Wetropa: Plastic packaging and sustainability go together

The specialist for plastic packaging Wetropa from Mörfelden near Frankfurt am Main shows that economic interests and ecological responsibility can indeed be reconciled. The company has specialised in foam processing since 1970. And industry and trade benefit in many ways from the innovative packaging solutions from the South Hessian company.

The company's production and development activities have long Environmentally friendly processes plays an important role. Even when selecting the materials, attention is paid to maximising durability and reusability. Recyclability and CO2 balance are decisive criteria for the use of raw materials. Only CFC-free foams manufactured in accordance with current environmental regulations are used. With a strong commitment to environmental protection and targeted innovations, the company proves that it is ideally positioned even in times of crisis.

„Our declared goal is to be the most sustainable company in the foam processing industry by 2025 - with the majority of materials processed being recyclable.“ Dirk Breitkreuz, CEO Wetropa

Volatile markets: flexible ideas needed

„Innovative solutions and reducing the carbon footprint are decisive competitive factors in the highly competitive packaging market,“ says CEO Dirk Breitkreuz, summarising his philosophy in a nutshell. He is always pursuing new and interesting goals with his company. Perhaps this is because such far-sightedness is a matter of course for him. Previously, the enterprising entrepreneur produced microlight aeroplanes. The distanced view from above is an everyday challenge, so to speak.

In 1995, he sold the company and took over the Plastics processor Wetropa. What convinced him at the time was the manageable size, the good customer base and the immense development potential. He recognised the great potential of the small company at an early stage. Innovative products for diverse target groups and markets could be developed here.

With Breitkreuz, 1995 saw the Reorientation towards the packaging market and specifically on industry and the manufacturing sector. The one-sided focus and high dependence on the construction industry were a thing of the past. Where previously almost exclusively foam pipe insulation had been manufactured, a far-reaching diversification was now established.

The beginning: mattresses for the military

We had completely different markets and perspectives Company founder Peter Eismann 1970 in mind. But even then it was all about foam. With four employees, he began manufacturing mattresses for the American military in a garage.

In 1974, the company moved to the Niedereschbach industrial estate in the north of Frankfurt. A proud 1,200 square metres of production space was available here, and the number of employees grew to seven.

Broader orientation: differentiated processing options

Dirk Breitkreuz then forced the Broader orientation The company has specialised in a wide range of sectors such as the automotive and supplier industry, medical, measurement, sensor and laser technology. Since then, customers have included the tool industry, the electronics sector and aerospace companies as well as the optical industry and equipment and apparatus engineering.

Today, the chemical and cosmetics industries also rely on Functional packaging solutions from Wetropa. Even art and culture and the packaging trade make use of the development and manufacturing expertise of the company from Mörfelden.

The company has grown continuously since the end of the 1990s. In 1999, the company moved to its current location with a production and storage area of 3,000 square metres. The latest expansion of the production, office and warehouse space to around 7,000 square metres in 2016 was the logical consequence of the company's steadily growing potential.

In order to be able to process foams flexibly and creatively all processing options offered: Laminating, splitting, cutting to size, contour cutting, punching, milling, welding, gluing, water jet cutting or laser labelling. Since 2014, the processing of PP sheets for load carriers has opened up additional industrial fields of application.

For safety: certified processes

The company has complied with the ISO 9001 quality management standard since 2002 and has also been certified to ISO/TS 16949 since 2011, thus meeting the quality criteria of the automotive industry. But Wetropa has also done a lot to optimise production and processes beyond this. For example, three to five percent of annual turnover is invested in green technologies and ecological commitment as well as in technical equipment and the modernisation of the machinery.

The positive development also left its mark on the employees, who have always supported this development. In 2012, Wetropa was awarded the TOP JOB 100 employer seal of approval. Today, the approximately 130 qualified specialists generate a turnover of 18 million euros. With the acquisition of Münchner Schaumstofftechnik GmbH in 2013, the company's presence in southern Germany and the DACH region was further expanded. And finally, an office was opened in Zurich in 2017.

Exceptional: products and processes

Innovative products and processes have long been one of the company's specialities. The company was one of the first to Moulded foam parts and the Labelling of foams by means of laser marking made possible. The Wetro case (pictured above) made of high-quality foam can be opened like a suitcase, for example. The functional interior, which is perfectly adapted to the product, provides optimum protection for the contents and can be attractively presented at the same time.

Today, professional labelling of plastic parts with the specially developed WPS labelling system is standard, instead of elaborately printing the plastic or simply sticking on a label. The system enables the Permanent marking of the foam. This means that reusable packaging systems and load carriers, such as those used in the automotive industry, remain clearly labelled throughout their entire life cycle.

The vision: CO2 neutrality

„A responsible approach to our environment and the preservation of nature is very important to us. The first step years ago was the Certification of our environmental management system, which is firmly integrated into our day-to-day production,“ explains Breitkreuz. And so the company is continuously working on reducing its own CO2 footprint and expanding its activities in the area of sustainability.

The company was certified to ISO 14001 back in 2013. Since 2018, the experts have also been supporting climate protection projects and offsetting CO2 emissions that are unavoidable in the production process. The company works together with ClimatePartner, the leading solution provider for companies that want to neutralise their carbon footprint.

As far as the materials used are concerned, the declared aim is to use resources that are 100 per cent recycled. To this end, Wetropa already uses Development and design of new packaging solutions minimising the use of materials, waste avoidance and the Consistent waste utilisation.

The company collects unmixed waste from the production of the 100 per cent recyclable, non-crosslinked PE foams, regranulates it and processes it into Recyclate, which can then be fed back into the manufacturing process. However, packaging solutions have now also been developed which, despite the use of different materials, are 100 per cent recyclable and suitable for reuse in the production process. Almost all possible applications are suitable. And to curb marine littering and stop the global spread of microplastics, we support WWF projects.

For growth: digitalisation plus sustainability

Even in the current situation, Breitkreuz believes the family business is well positioned. The good credit rating, which was confirmed by the CrefoZert credit rating certificate in 2012, is certainly helpful in this respect. The crisis offers the opportunity to optimise processes and focus on the next important goals. The Managing Director has set his sights on streamlining the company's own structures and instructing employees to work and act even more independently.

Nor does the entrepreneur rule out further expansion. Indispensable on the way to even more sustainability is the Further digital transformation The aim is to network development, production and logistics even better.

There is no lack of forward-looking products, such as the High-tech packaging for the exclusive bike of a racing cyclist. This is a robust case with a customised PE foam insert for optimum storage of the shock-sensitive, high-quality racing bike.

In focus: new highly elastic plastic

Wetropa is working with JSP International, a listed company that has been a leader in the manufacture of high-performance, lightweight plastic products for over 60 years, to introduce the innovative ARPLANK foam material. The first result of the co-operation is a High-quality, highly elastic plastic made from expanded polyethylene (EPE). It already consists of up to 50 per cent recycled material and is 100 per cent reusable.

In terms of safety, this innovative product has proven to be one of the most effective packaging materials. At the same time, it is one of the lightest and most sustainable alternatives on the market. Since January 2021, the Wetropa Group has been supporting the market launch of ARPLANK in the DACH countries as a partner of JSP.