How Corplex is transforming industrial packaging into an efficient logistics tool

A Closed Life Cycle: Direct Manufacturer and Recycler Under One Roof

One of the key arguments for supply chain stability today is a clear material origin and control over its life cycle. As a direct manufacturer of corrugated plastic sheets, Corplex manages every step of production – from raw material processing to the finished packaging.
What makes this solution exceptional is that Corplex also operates as a recycler in the circular economy. This closes the material loop: it can collect old, damaged or discarded corrugated plastic packaging from customers, recycle it and return it to the production process. This approach directly aligns with PPWR requirements to support the circular economy and minimise landfilling.

From FEFCO Standards to Unique Custom-Made Solutions

The technological capabilities of the Hurbanovo plant enable Corplex to respond flexibly to a wide range of industrial needs – from simple layer pads to complex packaging systems. The company's portfolio includes:

• A wide range of material specifications: Production of corrugated plastic sheets (AkyLux®) in various basis weights and thicknesses, with functional treatments such as ESD protection for electronics or UV stabilisation.
• Standardised packaging according to FEFCO: Production of a wide range of designs based on the international FEFCO code, proven through years of use in industrial logistics.
• Bespoke manufacturing: Design of unique solutions that precisely match the geometry of parts, including complex inserts, retaining elements and textile-laminated dividers for maximum surface protection.

Innovation in the Details: Flat-Pack and Efficient Folding

The implementation of returnable packaging in industrial practice is often associated with concerns about storage capacity. Corplex eliminates this problem through the innovative design of solutions for picking bins and shelf bins.
Thanks to precision manufacturing and pre-creased folds, these products are supplied in a so-called flat-pack format. A warehouse operator can then assemble the bin in a few seconds with an intuitive movement directly at the shelf. The result is not only warehouse space savings and lower transport costs for empty packaging, but also a clean, dustproof environment that paper alternatives cannot provide over the long term.

Technical Support for the Transition to PPWR Standards

In practice, implementing the new PPWR standards requires more than simply changing suppliers. Corplex in Hurbanovo has its own design centre, where theory is turned into actual samples. The entire process is built on three pillars:

• Logistics flow analysis: Instead of relying on estimates, the actual stresses on the packaging, stackability and the reverse logistics cycle are examined.
• Custom prototyping: In-house capabilities make it possible to produce functional corrugated plastic samples within days. Customers can therefore test the packaging directly in their own operations before series production begins.
• Total cost calculation (TCO): Corplex demonstrates the efficiency of corrugated plastic by comparing costs per packaging cycle (Total Cost of Ownership). The data confirm that, with a higher number of cycles, returnable PP packaging becomes more economical than single-use solutions.

For industrial companies seeking a way to align their processes with the new legislation while increasing logistics efficiency, Corplex Slovakia is an experienced partner with direct manufacturing and recycling capabilities.