Total Cost of Ownership optimisation in dairy logistics
The dairy industry is facing increasing efficiency and cost pressure. At the same time, regulatory requirements are tightening, for example through the PPWR. Packaging must become more sustainable without compromising transport safety. Data-based Total Cost of Ownership (TCO) analyses can help reduce material costs, optimise processes, and ensure compliance with legal requirements.
The true cost drivers
In the dairy segment, large quantities of pallets are moved every day. In addition to the direct film costs, material waste, energy consumption, unstable loads, and complaints are the main cost drivers. High-quality blown films offer a major lever here: due to the nature of the manufacturing process, material usage can be reduced by up to 30% compared with conventional cast film, while at the same time increasing holding force and resistance.
Cast vs. blown film
Whether cast or blown film is more economical depends on the application scenario. Cast films are characterised by high clarity; they are cost-effective and suitable for lighter loads. Blown films offer higher strength, elongation and temperature resistance and are therefore used for heavy, sensitive packaging or irregular load units. A TCO analysis takes into account not only the film price but also the number of wraps, material consumption, complaint costs and downtime.
Process analysis and valid test procedures
DUO PLAST offers dairies a structured TCO audit (Total Cost of Ownership): it analyses material consumption, process parameters, load security, complaint data and regulatory requirements. In its own DUO LAB test centre, pallets are tested in vibration, acceleration, braking and climate tests. This makes it possible to simulate load profiles and determine optimal wrapping parameters. High-performance films such as DUO RUNTEC (100% virgin material) or DUO EARTH 5 (35% PCR) require up to 30% less material compared with a 17 µm cast standard film and reduce CO₂ emissions by up to 30%; at the same time, the probability of complaints decreases.
TCO analysis – the key to cost certainty and sustainability
Why act now?
The combination of increasing cost pressure, growing competitive pressure and strict regulations makes a sound total cost analysis indispensable. The PPWR obliges distributors to achieve higher recycling and reuse rates from 2030 onwards. Regardless of this, avoidable costs arise through inefficient transport packaging. Early analysis helps to identify risks and to prioritise investments.
What does a TCO analysis include?
DUO PLAST considers the costs that can be optimised through material savings, improved film performance, correct machine settings and regulatory compliance (emissions, recycled content):
Material consumption and film selection:
By using state-of-the-art high-performance blown films, up to 30% of material can be saved while simultaneously reducing greenhouse gas emissions by around 30%.
Wrapping process and machine settings: optimal pre-stretch and the correct film thickness significantly reduce the cost per pallet while at the same time lowering energy consumption.
Pallet stability and complaints: through vibration, braking and climate tests in the DUO LAB, we check the stability of the load units under real transport conditions.
Regulatory compliance: the analysis takes into account PPWR requirements, PCR content and possible EPR fees where necessary.
Typical procedure and expected results
Preparation and data collection: inefficiencies often arise at the machine. Therefore, existing lines and film settings are analysed. Film consumption, machine settings and load unit stability are recorded.
Analysis and tests:
Wrapping tests under laboratory conditions – vibration, acceleration, braking and climate tests – provide precise comparisons between the film in use and DUO PLAST films.
Evaluation and action plan:
We support the implementation of the solutions and ensure through regular monitoring that the savings remain effective in the long term.
Implementation and monitoring:
The results show potential savings and provide recommendations on film selection, machine settings and process adjustments.
Your added value
A TCO analysis relieves production and logistics teams, saves real costs and helps with preparing for future regulation. Those responsible gain transparency, more reliable processes at the end of line and greater planning certainty.
