Every year 60,000 pallets loaded with spare parts and equipment are shipped by air around the world from Alfa Laval’s four main distribution centres.
A Small Change with a Big Sustainability Impact
Innovation in Alfa Laval components continues to advance. However, one essential element in shipments had remained unchanged for years: the wooden pallets.
In 2019, these pallets came under scrutiny as part of the company’s strategic focus on sustainability.
Rethinking Pallet Usage: A Black Belt Kaizen Initiative
Abbas Habib, Sustainability Manager in Parts Distribution & Logistics/Sourcing, carried out a black-belt kaizen project focused on pallet usage.
During this review, he identified that switching from traditional Euro pallets to lighter pallets could significantly reduce both costs and carbon emissions.
Significant CO₂ and Cost Reductions
Today, all Alfa Laval Global Distribution Centres use the lighter pallet.
The results:
- 1,691 tonnes reduction in CO2 emissions
- €1.3 million reduction in freight and material costs
These figures demonstrate the powerful impact that reviewing operational details through a sustainability lens can deliver.
Challenging Long-Standing Assumptions
“The light pallet was less than half of the weight of the Euro pallet, and we could not find a reason that made it necessary to use the heavier ones,” Abbas explains.
“It wasn’t a quality requirement; it wasn’t a safety requirement; it was just what we had always used.”
A pilot project confirmed that switching to lighter pallets would meet all quality, safety, and customer requirements.
Phased Rollout Across Distribution Centres
The transition began in 2020, starting at DC Tumba, and was gradually implemented across other sites over the following two years.
“We have had a very good response from customers and colleagues. It’s a win-win from all angles,” says Abbas.
Additional Sustainability Improvements
The pallet initiative is part of a broader sustainability drive, including:
-
Replacing plastic wrapping with paper
- Using envelopes instead of boxes for spare parts
- Introducing cardboard pallet frames instead of wooden alternatives
A Mindset Shift Towards Sustainability
“It’s not easy to change but it’s obvious when you see these figures,” Abbas says.
“When you put sustainability at the forefront of your thinking, you can see the benefit for people and the planet.”
Importantly, the initiative did not require major process investments or increased workloads.
“It has just been a matter of changing the mindset.”
Encouraging teams to question established practices has sparked new ideas, including exploring ways to encourage customers to reuse pallets.
Continuous Improvement Towards Carbon Neutrality
Alfa Laval is not stopping at one successful initiative. The company is continuously striving to increase sustainability and reduce carbon emissions.
With a target to become carbon neutral by 2030, a range of initiatives across scopes 1, 2, and 3 emissions will contribute to achieving this goal.
Lifecycle Support and Global Service Network
Beyond equipment supply, Alfa Laval Marine Solutions are backed by a comprehensive global service network. Lifecycle support, including maintenance, spare parts, system upgrades, and technical expertise, ensures that marine systems continue to perform optimally throughout their operational life.
Access to genuine Alfa Laval spare parts and certified service engineers helps minimise downtime and protects the long-term value of onboard equipment. This focus on service and support is particularly important for vessels operating on tight schedules and in remote locations.
Trusted Solutions for a Changing Marine Industry
Alfa Laval Marine Solutions continue to set the standard for efficiency, reliability, and environmental responsibility in the maritime sector. By addressing the core challenges faced by shipowners and operators, Alfa Laval provides technologies that not only meet today’s demands but are also designed with the future of shipping in mind.
As the industry evolves toward cleaner, more efficient operations, Alfa Laval remains a trusted partner, delivering innovative marine solutions that support performance, compliance, and sustainability at sea.
Post inspired by Alfa Laval.
How Can We Help?
Get in touch with us if you need a quote or have any technical questions.