The major contribution of this research is to show that the
practice of reverse logistics concerning the use of returnable packaging
can bring important results for the logistic process in terms of
technical, economic, and environmental benefits.
We attempted to standardize a returnable packaging model to
replace the disposable packaging, the current model used by the
company studied. Using the returnable packaging model proposed,
it was possible to reduce the amount of disposable materials
consumed resulting in cost reduction, greater protection for the
products exported, reduction of waste generation at the final
customer, and logistical benefits such as reduction in volume
occupied by the empty packaging during the reverse flow of empty
packaging, which allowed that for every seven containers of
products shipped for export, only one container would return with
empty packaging.
The cycle time was 105 days, and the amount of returnable
packaging required to meet the flow of products was 1313. Within
the context of this study, the company considered these characteristics
satisfactory.
All relevant costs related to the returnable packaging model
proposed were considered, and the unit cost of the returnable
packaging was R$ 13.57 per engine head exported. This value was
presented to the company for more studies, and it expressed
interest in adopting the model developed in its logistics system.
The returnable packaging model resulted in the use of 18.00%
less material when compared to the disposable packaging model,
presenting economic and environmental gains by reducing material
consumption and waste generation.
With regard to the environmental performance assessment
using the LCA technique, the returnable packaging model was the
best alternative since it had the lowest levels of environmental
impacts compared to those of the model of disposable packaging.
The most important categories of environmental impacts were
GWP, ADP, AP, and POCP, in this order, being GWP especially more
relevant for the returnable packaging, while all other impact
categories were most significant for the disposable packaging
model. Therefore, the returnable packaging model developed was
the most feasible alternative presenting less impact on the environment.
However, improvements in the proposed model are
necessary, especially in terms of reducing the GWP.
Suggestions for further studies include:
Study the process of traceability of returnable packaging since
it is an important issue that could compromise the operational
integrity of the logistics process
Modify or replace the metallic rack with a similar material
since it was the factor that contributes the most to the majority
of environmental impacts related to the returnable packaging
model, especially for the GWP. Furthermore, this material was
responsible for most of the total weight of the empty packaging
(90%) during packaging reverse flow, which results in an
increase in transportation costs.