Brewing to net zero: Introducing sustainable new keg pallets for Grolsch made of 100% recycled plastic

Brewing to Net Zero: The Royal grolsch brewery and Schoeller Allibert introduce sustainable keg pallets made of recycled plastic

Hoofddorp, February 20 2025 – Sustainable reusable packaging specialist Schoeller Allibert and Dutch brewery Royal Grolsch are taking a further step towards a circular economy with their latest joint project: sustainable pallets made from recycled plastic. 

 The Royal grolsch brewery is combining centuries of brewing craftsmanship with a forward-thinking approach to sustainability. Based in Enschede, Netherlands, the brewery has partnered with Schoeller Allibert to introduce a sustainable packaging solution: new keg pallets made from 100% post-consumer recycled plastic. This initiative supports Grolsch’s goal of achieving net-zero emissions by 2030, reducing CO₂ emissions and transportation costs.

Old pallets, new problems

The old keg pallets no longer met Grolsch's operational and sustainability needs. Their heavy weight raised transport costs and CO₂ emissions, while outdated molds made them difficult to source and less reliable. Grolsch required a more sustainable and efficient alternative.

“Replacing these pallets was an excellent occasion to consider their environmental implications,” says Joost Nawijn, Packaging Material Development Specialist at Koninklijke Grolsch. “That's why we wanted a lighter pallet made from recycled material, thus a more sustainable solution.” 

Solution for the circular economy

No big task for Schoeller Allibert: the reusable packaging specialist delivered a tailor-made keg pallet that meets all the brewery's requirements. The new load carriers are made of 100 percent post-consumer recycled plastic and are also 12 kilograms lighter than their predecessors. Grolsch can therefore significantly reduce the material used. 

How has Schoeller Allibert achieved this? The designers achieve the reduced weight of the pallet with the special honeycomb structure, but also through a different production technique. Instead of using a low-pressure process, the experts manufacture the keg pallets using a high-pressure injection molding process. The recycled plastic comes from post-consumer material – i.e. used bottles and packaging that are collected, sorted, cleaned and processed into new products. On the other hand, old pallets (post-industrial material) are also used. This reduces emissions by 83 percent^* compared to pallets made from virgin materials. Once the load carrier has reached the end of its life cycle, Schoeller Allibert takes it back and recycles it. An example of a functioning circular economy.    

Optimum handling, individual design

The new pallet offers even more features for the brewery's day-to-day operations. The honeycomb structure makes it lighter and stronger. Forklift trucks can also pick it up more easily thanks to the smoother fork entries, which means that hardly any damage occurs. The stackable design enables a seamless transition between old and new pallets, allowing the user to use both versions in parallel. In addition, the stackability reduces the space required for return transportation, which also reduces CO₂ emissions – as fewer trips are required.  

The new pallets have been in use since January 2025. The close cooperation between Schoeller Allibert and Grolsch resulted in a perfect solution in which improved utilization function, reduced CO₂ emissions and cost savings go hand in hand.  

“Our intelligent solutions are tailored to the requirements of the Grolsch brewery,” summarizes Vincent Vos, Head of Design at Schoeller Allibert. “To achieve this, our experts listen to what the customer needs, develop a solution and test it until it is successful.”

Looking ahead

Since January 2025, Grolsch has been using these new pallets, and the results have already demonstrated their effectiveness. This collaboration showcases how innovative packaging solutions can help companies meet their sustainability goals while improving logistical efficiency. With these new pallets, Grolsch is making significant progress towards achieving net-zero emissions.

At Schoeller Allibert, we’re proud to be part of this journey, providing packaging solutions that support a circular economy and make a real difference for the planet.