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A ZENTEK Group initiative

Material flows

Whether in closed material loops – where packaging is turned back into products of equal value – or in open material flows with a wide range of new applications, what really matters is that used packaging is collected, processed and returned to the cycle. That way, raw materials stay in circulation, costs go down and sustainability becomes measurable.

Targeted material flow management turns waste into valuable resources.

Packaging is a vital component of all supply chains and one of the largest sources of waste. Under the new EU regulation (PPWR), packaging must be designed and recycled in such a way that it remains in the system. Material flow management plays a key role here, with producers, distributors and brands required to provide transparent documentation detailing how their packaging is collected, recycled and returned to the cycle.

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Abbildung, die die drei Schritte eines Joghurtbechers zeigt: den Becher selbst, die PET-Flocken und schließlich das Kunststoffgranulat.

Feedstock

After use, packaging is collected and sent for recycling.

PET-Flakes

The collected waste is cleaned and shredded to produce PET flakes – small slivers of plastic that serve as an intermediate product for further processing.

Plastic granules

High-quality PET regrind in the form of small pellets: the end product of mechanical recycling, which is used as a raw material for the manufacture of new plastic packaging.
Mitarbeitende mit Schutzkleidung und Helmen sortieren Verpackungen auf einem Förderband

The challenge

Regulatory requirements and sustainability targets must be met with certainty.

The solution:

Professional material flow management (MFM).

Regardless of the materials used, MFM keeps all packaging in the cycle, supports compliance with legal requirements and makes your processes transparent and controllable.
Diversity of material flows

From packaging waste to new product

Cycle illustration: Yoghurt cup becomes shampoo
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Added value for you at a glance

Savings and opportunities for optimisation

Compliance with legal requirements including ESG, CSRD and PPWR

Reduction of waste volumes and increase in recycling rates

Competitive differentiation and enhanced company reputation

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Manage your packaging responsibly and effectively

Packaging is now the focus of more attention than ever. It has a short life and creates large volumes of waste – but it also offers huge potential for reuse. Conventional packaging materials like plastics, glass, metal and paper – are the foundation of effective circular solutions. At the same time, an increasingly significant role is played by specific materials such as strapping and EPS packaging, which require tailored solutions.

High-volume material flows

Packaging made of glass, plastic, paper and metal

These materials accumulate in large quantities and are collected in established systems, such as Germany’s dual system, which have advance collection, sorting and recycling infrastructures. The focus here is on standardised, efficient processes and on ensuring legal compliance.

Specific material flows

Packaging such as strapping and EPS

In contrast, some packaging and auxiliary materials – for example, strapping or EPS (polystyrene) – are currently unutilised or even considered contaminants. These material flows can be recycled using tailored collection and recovery concepts.

PPWR makes material flow
management essential.

Design for recycling (D4R)

Packaging must be designed in such a way that it can be recycled.

Use of recycled materials

Plastic packaging must contain minimum percentages of post-consumer recycled material.

Transparency and evidence

Manufacturers must document material flows.

Extended producer responsibility (EPR)

Producers are responsible for collection and recycling.

Professional material flow management ensures the necessary legal conformity, reduces risks and also opens up economic opportunities. As a result, keeping packaging in the cycle delivers strategic advantages.

The PPWR – what you need to know now
  • Closed loop
    Example of a closed loop

    Material flow for strapping

    Used strapping accumulates in large quantities in many sectors. Professional material flow management ensures that all strapping is returned to the recycling loop in a way that is both resource-efficient and cost-effective.

    • Collection: Specialised partners gather the strapping centrally.
    • Compaction: The material is compressed into bales for optimised logistics.
    • Processing: Producer processes the material into high-quality regrind.
    • Manufacture of new products: The regrind is used directly as a secondary raw material in new strapping.

    Benefits: Saves raw materials, reduces costs, increases recycling rates, strengthens the circular economy.

  • Open cycle (downcycling)
    Open-loop solution with new potential uses

    Material flow for EPS (polystyrene)

    EPS packaging (e.g. parts used to protect equipment) can also be recovered through targeted packaging recycling – although this doesn’t create a closed loop.

    • Collection: EPS waste is gathered in containers and compacted on site using special compactors.
    • Transport & processing: Collection and transfer to processors who convert it into a secondary raw material of lower quality than the original material.
    • Production: Use of the material in the production of a new product that is not of equal value (downcycling).(Downcycling).
    • Typical application: Used to stuff a Zentifant.

    Added value: Reduces waste volumes, conserves resources, helps meet legal requirements.

As your partner, we will manage the entire range of material flows for you.

Every material flow has its own challenges and opportunities. Professional material flow management takes these differences into account, making it possible to not only collect materials efficiently but also specifically return them to high-quality recycling processes.

Glass

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Paper / cardboard

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Plastics

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Metal

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Your individual material flow

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We’re here to help you.

Whether you’re interested in finding markets for your waste, sourcing recycled materials or increasing recycling rates, we can help you to see packaging not as a waste disposal problem but as a source of valuable resources. With our holistic approach, we create solutions that fulfil economic, legal and environmental requirements simultaneously.

We will provide you with a solution that is both wide-ranging and in-depth:

Standardised,where possible and
Customised, where necessary.

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Mitarbeiter Zentek
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Support you can rely on.
You want to be certain that processes are effective, rules are followed and help is available whenever you need it. Our transparent, reliable and practical services are designed to satisfy all of these needs.
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Expertise

We continuously analyse and adapt to the latest requirements and market developments. We help companies understand which requirements are relevant to them now and which will be in the future.
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Advice

We take a practical approach to resolving individual issues, developing specific recommended actions that combine legal certainty with cost-effectiveness.
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Legal certainty

All processes – from packaging design to volume reporting – are based on current requirements. Companies act in compliance with the rules at all times.
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Implementation

From dual-system participation to reporting, in addition to planning measures, we also provide operational support until quantifiable results are achieved.
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Efficiency

Complex processes are structured, digitally supported and clearly documented. This reduces internal effort and creates space for core business activities.
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