Circular Glass Packaging Production at Vetropack Straža d.d.
Summary:
Vetropack Straža d.d. exemplifies circular economy principles by integrating high shares of recycled glass (cullet) into its production processes. By focusing on closed-loop systems and resource efficiency, Vetropack significantly reduces environmental impact while maintaining the quality and functionality of its packaging solutions.
Main description:
Vetropack Straža d.d. is one of the most prominent glass packaging manufacturers in Croatia and a key part of the Vetropack Group – a European leader in sustainable glass production. The company specializes in manufacturing glass bottles and containers primarily for the food and beverage industry, serving both domestic and international markets.
Every year, Vatropack Straža processes more than 250.000 tonnes of glass, integrating both virgin raw materials and recycled glass (cullet), which is sourced from post-consumer packaging waste (e.g. returned bottles) and internal production scraps. This approach reflects the company’s commitment to circular economy principles, where materials are kept in use for as long as possible.
In glass production, using cullet instead of virgin materials (such as sand, soda ash, and limestone) allows for lower melting temperatures, which means lower energy consumption, reduce CO2 emissions during the manufacturing process and preservation of natural resources by reducing the need for new material extraction.
Vatropack has developed a highly efficient sorting and processing system for cullet, working in partnership with local waste management operators and suppliers to ensure the input material is clean and high-quality. According to the company’s sustainability reports, increasing cullet content by just 10% results in 2.5-3% energy savings and 5-7% reduction in CO2 emissions. Thanks to these efforts, some of Vetropack Straža’s production lines today operate with up to 85% recycled glass, depending on the color and type of product. This dramatically enhances the environmental performance of their packaging while maintaining the durability, hygiene, and recyclability of glass. In addition to its operational excellence, Vetropack Straža is recognized for its consistent investment in energy efficiency, employee training, and environmentally responsible business practices – all of which align with the broader Vetropack Group’s vision for climate neutrality and circular production.
Resources needed:
Continuous supply of high-quality, sorted cullet, echnological upgrades for energy-efficient melting furnaces, partnership with waste management and recycling systems, and internal quality control for cullet purification and integration
Environmental benefits:
The company achieves significant environmental benefits by integrating high shares of recycled glass (cullet) into its production process. For every 10% increase in cullet usage, the company reduces CO2 emissions by approximately 5-7%, while achieving 2.5-3% energy savings. By incorporating post-consumer glass waste into new glass production, Vetropack not only lowers its carbon footprint but also minimizes the use of virgin raw materials such as sand, soda ash, and limestone. This contributes to the conservation of natural ecosystems and reduces the environmental impact associated with raw material extraction.
Economic benefits:
Vetropack Straža generates notable economic benefits through the increased use of recycled glass (cullet) in its production. By reducing energy consumption, operational costs are significantly lowered, especially in energy-intensive melting processes. At the same time, raw material costs are reduced by decreasing dependence on virgin inputs such as sand, soda ash, and limestone, which are often more expensive and subject to market volatility.
