Paper has several advantages over plastic: a plastic reel weighs 217 grams, while a paper reel weighs only 140 grams, a reduction of around 35%. Extracting the raw materials, producing, and disposing of a plastic reel generates approximately 1,075 kilograms of CO₂ equivalent emissions¹, while a paper reel generates only 203 grams, a decrease of around 80%. In some regions, fees are even charged for plastic disposal, whereas paper is more recyclable and biodegradable.
In concrete terms: if ams OSRAM were to replace more than half a million plastic reels with paper reels each year, it could save 108 tons of plastic and 436 tons of CO₂ emissions. At the same time, transport weight would be reduced by 38.5 tons per year. Therefore, using paper not only saves on transport costs and waste, but also reduces CO₂ emissions throughout the entire supply chain, from production to disposal.
Sustainability meets industrial suitability.
The stability, handling, and cleanliness of the paper reel meet the stringent requirements of LED manufacturing and product safety. In exhaustive testing, ams OSRAM and the Zumtobel Group were able to demonstrate that the paper reels offer performance characteristics comparable to those of plastic reels. The paper solution also delivered excellent performance on the industry-standard SMT line, the highly automated production line for placing electronic components onto printed circuit boards, maintaining the same efficiency and shape. Particle safety was also confirmed, meeting the stringent cleanroom requirements. Furthermore, the paper reel is designed to hold the same number of components as its plastic counterpart.
“The paper reel was developed through a trust-based collaboration with our project partner, the Zumtobel Group, driven by our team in Malaysia,” says Martin Bachler, Sustainability Director at ams OSRAM. “If you want to be more environmentally friendly, you have to challenge established standards, and that requires openness and courage.” “Our collaboration with ams OSRAM on the sustainable paper reel confirms once again that sustainability is a team sport,” says Bernhard Apsner, Senior Director of Global Technical Procurement at the Zumtobel Group.
“We are proud to have initiated this project and to have collaborated on the development of a resource-efficient packaging solution. This project aligns with the Zumtobel Group’s sustainability strategy, which is gradually transforming us into a more sustainable company and encouraging us to work with our customers and partners to shape a more sustainable future.” ams OSRAM and the Zumtobel Group collaborated to develop the idea into a market-ready solution. The paper reel is currently in an advanced pilot phase and has already successfully passed customer evaluations. Sustainability without additional costs: Whether plastic or paper, material and production costs are comparable, while savings in logistics and waste disposal deliver long-term cost advantages. The paper reel improves key sustainability indicators, such as carbon footprint, material use, and waste prevention throughout the supply chain, and helps customers meet their ESG requirements.
Further steps are already being explored to expand and integrate other product lines, such as automotive components. Recycling is another area that is being actively promoted in order to consistently apply the concept of a circular economy.
