The unknown causes of water losses in the cooling cycles of the injection moulds had resulted in higher costs and, in some cases, even downtime at ALPLA North America. Digital pulse flow water meters attached to the pipes were used to determine losses caused by mould changes, leaks and tank overflows. In addition, specially programmed alarms now warn of excessive water consumption. As a result of these measures, the consumption of 16 of the 22 monitored facilities was significantly reduced by a total of 970 cubic metres of water. Avoiding the use of chemicals to treat this water volume has a positive impact on the environment and reduces costs.

Back in early 2021, the team at ALPLA’s Indian plant in Silvassa in the union territory of Dadra welcomed 27 young female engineers and female university graduates. Eleven other female employees followed in the course of the year. A further 13 women were recruited at other plants throughout the country. ALPLA also supports the women with accommodation, a safe work environment and transport, and in so doing is increasing the proportion of women in industrial occupations in India.

In Dubai, a team of ALPLA employees initiated a project to plug air leaks. Any leaks are identified in systematic monthly measurements performed on the running machines. This ensures that the infrastructure, machinery and pipes are free of leaks at all times, thereby eliminating downtime. The installed device also measures the effects of a leak and the possible losses until the fault is rectified.

Non-reusable waste at the plant in Bridgwater was reduced from 497 kg a month in 2016 to an average of just 95 kg in 2021. This was achieved by raising the employees’ awareness of their moral responsibility, by means of real dedication and based on process changes implemented in close cooperation with the customer. Among other things, the following points were implemented:

Raising awareness among all the employees Clean floor guidelines Two-container system for waste Black waste container sorting – materials engineer performs a check before disposal to ensure that as much as possible is recycled

Under the motto of ‘Green to Green’, ALPLA initiated the use of 100 per cent green rPET bottles to replace the conventional 100 per cent virgin-material PET and glass bottles used by the Slovenian mineral water company Donat. The decision to cease using newly produced PET bottles and reusable glass packaging has resulted in reductions in CO₂e emissions of up to 90 per cent.

The green PET bottles which are commonplace in the Slovenian market are collected in Slovenia and recycled in Wöllersdorf, to then return to supermarket shelves as new rPET bottles.

In the case of this project, the customers’ expectations were exceeded thanks to a great deal of commitment. Here, Germany’s familiar ‘pearl bottle’ was redeveloped as a reusable PET bottle. The requirements were that there be a 10 per cent rPET proportion and that it be possible to refill the bottle 15 times. Ultimately, an rPET proportion of 30 per cent was achieved and they are now working on creating a closed loop. The bottles have been in production in Exter since March 2021 and the target is for 25 million bottles a year to be supplied. The project boasts an obvious advantage – a lower carbon footprint thanks to the higher rPET proportion, renewable energy and up to 15 cycles.

In Brazil, ALPLA employees organised various projects designed to support social initiatives and charitable organisations in the area of sport and education. The projects included the follo wing:

Supporting children’s homes Blankets for shelters for the homeless Food donations for the production workers during the coronavirus pandemic Christmas presents for orphanages and schools Winter clothing campaigns for employees Welcome gifts for newborn babies at all ALPLA plants in Brazil