Studies show: Multiple use of strapping bands massively jeopardizes transport safety - Mosca fights for EU exemption

The EU Commission is currently discussing an exemption (delegated act) for strapping as part of the Packaging and Packaging Waste RegulationPPWR), which came into force on February 11, 2025. The PPWR aims to reduce packaging waste and promote the circular economy through recycling. It also provides for mandatory reusable quotas for strapping (so-called reuse). Mosca and the strapping project alliance have already submitted a comprehensive, independent position paper to the EU Commission containing detailed study results. "We welcome the objectives of the PPWR, but the safety of transported goods and the stability of supply chains must remain guaranteed. And this is not the case with multiple use," explains Dr. Martin Bussmann, Deputy Chairman of the PAU and Head of Material Innovation at Mosca. "The position paper provides a reliable, fact-based foundation that the EU Commission should definitely incorporate into the exemption."

The PAU is an association of 13 leading European companies in the strapping industry, including Mosca, Teufelberger, Fromm, Sekisui and Messersi.

Technical studies prove safety risks during reuse and multiple use

The scientific basis for this requirement is provided by independent technical tests, including those carried out by the Fraunhofer Institute for Microstructure of Materials and Systems IMWS at the Mosca Tech Center in Waldbrunn. The focus was on mechanical and thermomechanical testing in accordance with international standards, including the horizontal force test in accordance with the EUMOS 40509 standard, the ISTA 1E inclination and vibration test and tensile tests on various belt areas, particularly on the critical weld seams.

The results are alarming: after just one use, the welds on polypropylenePP and polyethylene terephthalatePET strapping lose an average of 47 to 60 percent of their breaking strength. With repeated use, the tensile strength of PP in particular decreases by up to 34 percent. Additional thermal stresses caused by temperature fluctuations between +40 °C and -30 °C lead to additional stresses in the tapes. This further weakens the material in practical use. It is particularly problematic that such stresses cannot even be documented under real transport and storage conditions.
"These values make it clear that reuse poses a considerable safety risk for goods and people," explains Dr. Martin Bussmann. The project alliance is therefore in favor of a pragmatic regulatory solution. Instead of relying on potentially dangerous reuse, the use of high-quality post-consumer recyclates should be strengthened and strapping bands should be exempted from blanket reuse quotas. This is the only way to ensure permanently safe and resource-conserving transport packaging. "In addition, the more frequently a Strap is used, the more often it needs to be checked and maintained. This is hardly technically feasible and economically disadvantageous."

Reusable solutions are often less sustainable than expected

From an ecological point of view, blanket reuse is also not a viable solution: a study commissioned by the Project Alliance from the Gesellschaft für Verpackungsmarktforschung mbH (GVM) clearly shows the limitations of current reusable strapping systems. Standard market alternatives such as mesh boxes with tension straps, tension straps with tarpaulins and strapping bands with tension clips were analyzed in terms of safety, reusability, environmental impact and cost-effectiveness.

Technically, alternative variants showed significant weaknesses: strapping bands with clips, which are the most similar to disposable strapping bands, lose significant tensile strength and elasticity after just two cycles of use, which are key properties for load securing. Tension straps with tarpaulin achieve 50 to 150 cycles depending on use, but are highly susceptible to UV radiation and wear out quickly if used incorrectly. Mesh boxes with tension straps theoretically offer 200 to 300 cycles, but are heavy, bulky and unsuitable for recurring applications as this would involve a lot of maintenance and documentation.

In addition, the necessary return transportation of reusable components, which often has to be carried out over long distances within Europe, causes considerable additional logistical costs. This includes additional transportation routes, resulting in increased CO₂ emissions, higher storage and personnel costs and the need to provide replacements in the event of loss or defects. Especially in heterogeneous supply chains with changing customers, it is almost impossible to set up a functioning reusable system. "The results clearly show that the effort involved is disproportionate to the benefits," explains Dr. Bussmann.

Sustainability: disposable strapping is often more advantageous

A supplementary life cycle analysis also shows that disposable strapping has a better carbon footprint than reusable alternatives in many cases, despite being used only once. The low material usage, low weight and good recyclability make strapping a resource-saving packaging material, especially when it is made from post-consumer recyclate.

"Integrating these facts is crucial when we talk about ecological responsibility," Dr. Bussmann continued. "Pure symbolic politics won't help. We need solutions that are practicable, safe and demonstrably sustainable."

"Project Alliance Strapping" continues its commitment

The PAU continues to work resolutely towards a sustainable circular economy, including through the increased use of post-consumer recyclates in strapping. The alliance is working to close material cycles and thus significantly reduce the consumption of resources. "The PAU stands for practical solutions that combine safety and sustainability," concludes Dr. Bussmann. "We will continue to contribute our expertise in the future - in dialog with politics, industry and society