Packaging and reduction of plastic

A team of employees at our Berlin site has developed a new packaging concept for our DIAvent® product. It replaces the conventional plastic blister packs with casings made from renewable, FSC-certified molded fiber paper that is certified as compostable in industrial composting facilities. This step does not only eliminate plastic waste – it also meets strict cleanliness requirements, reduces CO₂ emissions caused by the packaging compared with the previous plastic blister solution and can be scaled to other sites and products.

Meanwhile, the consistent use of strapping bands instead of stretch film at our Reichelsheim site is paying off. When packaging membranes on pallets, the straps save us around 70% in time and costs and reduce CO₂ emissions by a similar amount. And the machine reduces the physical strain on employees. Now they only need to move the pallet to the machine, which then handles the packaging process autonomously. Exerting physical strength, bending down, kneeling and walking around the pallet – all of that is eliminated.

Employee development

At our Plymouth site in the United States, we redesigned our Academy to promote continuous, self-directed learning. Equipped with modern video tools, podcast studios and flexible training rooms, the Academy supports employees in creating high-quality learning content. A new digital platform provides easy access to tutorials and resources – and underscores our commitment to employee development and a culture of lifelong learning.

At our Plymouth site in the United States, we redesigned our Academy to promote continuous, self-directed learning. Equipped with modern video tools, podcast studios and flexible training rooms, the Academy supports employees in creating high-quality learning content. A new digital platform provides easy access to tutorials and resources – and underscores our commitment to employee development and a culture of lifelong learning.

Digitalization & resources

The Weinheim stamping facility has developed a coil width calculator, a tool for determining the width of steel coils. This intelligent planning tool optimizes coil utilization for nearly 5,000 different products. By reducing production waste, the plant saves 240 tons of steel per year and eliminates around 450 tons of CO₂ emissions. The solution also improves inventory management and is now available as a mobile app. This project, which has already been shared with other FST sites as a best practice, demonstrates how digitalization, operational excellence and sustainability go hand in hand.

Electrification and automation enable us to reduce energy consumption in production at an increasing number of sites. In fact, some of the modern manufacturing cells we use consume less electricity than a customary toaster. Investing in electrified machines with lower electricity consumption pays off twice over: It reduces overall fossil-fuel emissions and protects us against future fluctuations in energy prices.

In addition, a high-performance microgrid battery system at our Berlin site helps balance peak loads and buffer fluctuations in electricity from renewable sources. This system helps us reduce energy costs and makes it possible to profitably trade electricity through AI-controlled load management. With this step, we contribute to grid stability – a prerequisite for integrating more electricity from renewable energy sources into the grid.

Supply chain & safety

We continuously encourage our suppliers to reinforce their safety and compliance programs. Our colleagues in India have launched their own supplier initiative, “SaFety First,” which aims to work closely with suppliers to improve safety standards and optimize the working conditions at their facilities. This program emphasizes active participation by the management and strengthens responsibility for ensuring safe working conditions and full compliance with the applicable regulations.

Employees at several sites in Germany and Italy have focused on other effects. They worked out how to optimize the logistics flow between five plants and distribution centers in the two countries. Shipments are systematically consolidated to avoid low utilization rates. A milk-run model coordinates loading and unloading along clearly defined routes. Both of these measures helped reduce transport distances by 75,000 kilometers per year. In addition, two further initiatives are tangibly helping to reduce the associated CO₂ emissions. Intermodal transport was expanded, with road and rail each taking up a roughly equal share. At the same time, using HVO-powered trucks running on hydrotreated vegetable oil made it possible to lower the use of conventional diesel vehicles. The resulting CO₂ savings amount to around 26 tons per year. The new logistics process is proving stable and efficient, reduces costs and serves as a model for the continued development of the global supply chain at Freudenberg Sealing Technologies.