One of ESA’s key ESG priorities is reducing plastic use across the sealing industry. Through the ESG Working Group, member companies collaborate to share strategies and support the shift to more sustainable materials and practices.
In this newsletter issue, we highlight a practical example from TEADIT®, an active participant in the ESG Working group, which has recently transitioned its whole gland packings product family from plastic spool covers to cardboard spool covers.
Their experience demonstrates how operational change, coordinated and supported across several departments, can deliver measurable environmental benefits. Below, Julia Köder, Application Engineer at TEADIT, shares how they planned and implemented this change.
In today’s industrial landscape, sustainability is no longer a buzzword, it is a necessity. At TEADIT®, we continuously strive to minimize our environmental footprint while maintaining the highest standards of product performance and customer satisfaction.
As part of our ongoing commitment to sustainability, TEADIT® has recently transitioned the whole gland packings product family from plastic spool covers (Figure 1) to cardboard spool covers (Figure 2).
Figure 1: Plastic spool covers in various colors and sizes
The transition from plastic to cardboard was motivated by several converging factors. Primarily, TEADIT® recognized its customers’ growing demand for sustainable and environmentally friendly packaging options. By shifting away from plastic, a material known for its environmental impact, TEADIT® aims to significantly reduce its plastic waste output. The switch also allows the company to simplify the packaging process, which was complicated by the use of plastic spools in a variety of colors.
Figure 2: Cardboard covers.
Standardizing the packaging not only improves efficiency but also aligns with the company’s broader efforts to reduce complexity across the supply chain.
Implementing this change required a cross-functional initiative involving several departments. TEADIT®’s Purchasing department evaluated new materials and suppliers, ensuring that the cardboard spools met both economic and quality standards. Quality Management played a critical role in testing and validating the new spools. The Production teams adapted equipment and processes to accommodate the new spool format, while the Sales department took the lead in communicating the benefits of this transition to our customers.
Key Actions in Transitioning to Cardboard Spools
- Selecting and Testing a Suitable Cardboard Reel Design
The transition from plastic to cardboard spools necessitated the development of a reel design that could withstand the mechanical stresses of winding and unwinding gland packing materials. The selected design had to ensure structural integrity, maintain product quality, and be compatible with existing machinery. Extensive testing was conducted to evaluate the durability, load-bearing capacity, and environmental resilience of the cardboard reels. This process ensured that the new spools met the rigorous standards required for industrial applications.
- Redesigning Spool Connectors for Compatibility and Durability
To accommodate the new cardboard spools, spool connectors were redesigned to ensure seamless integration with existing equipment. The connectors had to provide secure attachment points, facilitate easy assembly and disassembly, and maintain alignment during operation. Materials were selected for their strength and compatibility with both the cardboard spools and the gland packing materials. Prototypes underwent rigorous testing to validate their performance under operational conditions.
- Updating Bills of Materials (BOM) and Cost Calculations
The shift to cardboard spools required comprehensive updates to the Bills of Materials (BOM) to reflect new components, materials, and assembly processes. Cost calculations were revised to account for changes in material costs, manufacturing processes, and potential economies of scale. These updates ensured accurate budgeting, procurement planning, and financial forecasting, aligning with the company’s sustainability and cost-efficiency goals.
- Informing and Educating Customers About the New Packaging
Effective communication with customers was paramount to the successful adoption of the new packaging. Informational materials were developed to highlight the environmental benefits, functional advantages, and compliance aspects of the cardboard spools. Training sessions and support resources were provided to assist customers in adapting to the new packaging, addressing any concerns, and ensuring a smooth transition.
- Exploring Cost-Effective Procurement Channels
To support the new packaging initiative, procurement strategies were evaluated and optimized to source high-quality cardboard materials at competitive prices. Supplier relationships were assessed, and new partnerships were established to ensure a reliable supply chain. Bulk purchasing agreements and long-term contracts were considered to leverage economies of scale, reduce costs, and ensure consistent quality.
Overcoming Challenges
As with any significant change, the team encountered several challenges throughout the transition process. One of the main hurdles was achieving consensus across all customer segments, some of whom were accustomed to specific spool colors or formats.
The new cardboard spools required additional components to connect the lid and core securely, and our teams also had to invest time in training employees on the new system to ensure a smooth transition in daily operations. Despite these obstacles, the commitment to sustainability kept everyone focused and motivated.
Tangible Results of Transitioning to Cardboard Spools
By standardizing spool designs and eliminating the need for multiple plastic variants, the number of packaging items required for the gland packing product line was reduced by approximately 50%. This streamlined process not only simplifies inventory management but also contributes to a more efficient production process.
The consolidation of spool types has led to a more straightforward procurement process. With fewer variations to manage, ordering and stocking materials has become more efficient, reducing lead times and minimizing the risk of stockouts. This efficiency supports a more responsive supply chain and better aligns with just-in-time manufacturing principles.
The shift to a standardized spool design has allowed for larger volume orders of a single type, strengthening TEADIT®’s negotiating position with suppliers. Bulk purchasing of uniform components often leads to cost savings and more favorable terms, enhancing overall supply chain economics.
Transitioning to recyclable cardboard and metal spools has substantially decreased plastic waste associated with TEADIT® packaging. This move aligns with global sustainability goals and demonstrates our commitment to environmental responsibility. Moreover, the use of recyclable materials facilitates easier disposal and recycling processes for end-users.
These outcomes underscore the multifaceted benefits of adopting sustainable packaging solutions, reflecting improvements in operational efficiency, cost-effectiveness, and environmental stewardship.
This initiative clearly reflects TEADIT®’s commitment to environmental responsibility. By adopting more sustainable packaging, we are not only responding to customer expectations but also actively contributing to a greener future.
The transition to cardboard spool covers is more than a packaging upgrade; it is a conscious step toward sustainable innovation. We are proud of our progress and will continue to seek out and implement practices that support both business excellence and environmental stewardship.
Julia Köder, Application Engineer, TEADIT
Member of the ESG Working Group at ESA