"Zero really means zero for us"

What exactly does ALPLA mean by the Zero Pellet Loss programme - and what strategic goal is the company pursuing with it?

Francisco Fallas:  For ALPLA, Zero Pellet Loss clearly means that plastic pellets and other plastic particles must not leave the plants for the environment. This is about protecting soil and water worldwide. If something does escape, it must be collected immediately in a controlled manner. Our claim is clear: zero means zero.

Stephan Hadamek: At the same time, this is not a new issue for ALPLA. Individual plants - such as Fußach, Austria - have been working intensively on this for many years, have done a lot of groundwork and laid important foundations. Around two years ago, this experience was pooled and the topic was transferred to a structured, global rollout - with a clear methodology, uniform standards and specific recommendations for all plants. Today, Zero Pellet Loss is no longer an individual commitment, but a globally anchored aspiration.

ALPLA works with a ZPL assessment tool. Why was it introduced?

Francisco Fallas: The tool was communicated worldwide in February 2025. Training sessions were then held for the people responsible at the plants and access to the tool was activated. The assessment consists of ten specific questions. A plant can only complete it if all questions are answered with "Yes". This ensures that the essential requirements have been implemented.

It's not just about ticking a box. At certain points, plants have to upload documents - for example, a layout on which possible hotspots such as drains or transfer points are marked. In this way, the topic is considered concretely and on a site-specific basis.

How far has the global rollout progressed at ALPLA?

Francisco Fallas: A total of around 160 to 170 plants are currently in scope. Over 100 have already finalised the assessment, around 35 are in the process, and around 25 to 30 have not yet started. This does not include plants that do not process pellets themselves or joint ventures.

Stephan Hadamek: In Europe, the topic is becoming even more relevant due to regulations, as pellet losses will have to be reported in future. Estimates are required for the first time for 2025 and must be submitted by the end of May 2026.

How often are inspections carried out? Is there a risk of the tool becoming a "check-the-box" exercise?

Stephan Hadamek: At the moment, checks are mainly carried out on a random basis when someone from our team is on site. Our experience shows that the factories take the issue seriously. If a plant says "yes", something has usually been implemented. In Europe, we are also currently discussing whether external audits should be introduced in future - an audit every three years is being discussed. In the next phase, we will focus even more strongly on the quality of the content. It's not just about ticking boxes, but about robust and effective measures.

What are the biggest challenges?

Francisco Fallas: Technically, it's about infrastructure: interception systems, filters and secure transfer points. But the mindset is just as important. Zero pellet loss comes on top of day-to-day business. This requires good change management. Clear responsibility is a decisive factor. That is why we have introduced a mechanism: Those responsible must regularly confirm that they are still in charge. This ensures that each plant has a clear contact person.

Are there differences between the individual divisions at ALPLA?

Stephan Hadamek: Yes, zero pellet loss is much more demanding, especially in recycling. Large external surfaces, bale storage and mechanical processes lead to more potential sources of loss. In the classic packaging sector, risks are often locally focussed and therefore easier to eliminate.

What next steps are planned?

Francisco Fallas: The ten questions remain. However, we are improving the structure and evaluation and giving the regions themselves more responsibility. We are also publishing a best practice catalogue and clarifying other EU requirements, such as reporting, possible external audits and their implementation. This will be an important topic for the coming years.

In conclusion: If we look five years into the future, where should ALPLA be with Zero Pellet Los?

Stephan Hadamek: Our goal is clear: no more leaks - zero in the literal sense.

Francisco Fallas: In the long term, we would even like to get to the point where we avoid material losses in principle, meaning that they are not caused in the first place.