Making sustainability measurable with Poly-clip System: Less material, lower energy consumption

Sustainability is increasingly becoming a decisive economic factor in the packaging industry, with rising energy prices, growing cost pressure, and stricter regulatory requirements forcing companies to rethink their processes.

Poly-clip System, a specialist in clipping machines and clip packaging solutions, demonstrated at Interpack 2026 how ecological and economic goals can be successfully combined: Through modern packaging solutions and machines that measurably reduce material usage, energy consumption, and CO₂ emissions while significantly increasing efficiency across the entire production chain.

Clipping: packaging with minimal material usage

A key approach lies in the “clipping” packaging principle itself. Products in clip packaging are sealed directly after filling without additional processing steps. This saves material, reduces energy consumption, and shortens process chains. Compared to conventional film or tray solutions, the packaging share is significantly reduced, while transport and storage processes also become more efficient.

An environmental study conducted by the independent institute Circular Analytics in Vienna (December 2025) highlights the environmental impact. Clip packaging reduces CO₂ emissions by up to 90 percent compared to conventional packaging such as cans, cartridges, or thermoformed trays, and requires only one to two percent of packaging material, whereas alternatives can reach up to 35 percent.

This makes clip solutions an active contribution to climate protection and supports the industry in achieving its sustainability goals. At Poly-clip System, this concept extends right down to the details: the SafeCoat coating of the clips used reduces friction and wear, thereby improving process reliability and extending machine service life.

As a result, not only are maintenance requirements reduced, but also the need for spare parts and resources.

Machine generation Green Series: ICA 4.3 with reduced energy consumption

On the machine side, Poly-clip System is driving the development of energy-efficient systems forward. The Green Series stands for reduced energy consumption while maintaining high performance. Improved drive technologies and standardized components ensure stable processes and easy integration into existing production lines.

The Green Series has recently been expanded to include the high-performance automatic double clipper ICA 4.3, which redefines efficiency: the machine combines increased performance with significantly improved energy efficiency. Thanks to optimized torque and a harmonized drive architecture, it operates particularly stably and resource-efficiently.

The integrated One-Cable-Technology reduces complexity, minimizes potential sources of error, and sustainably lowers energy consumption. Under full load, it is reduced by 10.7 percent compared to the ICA 1 (built in 2003). At the same time, the reduced number of components ensures higher availability and lower downtime. The overall concept not only conserves resources but also reduces costs and enables users to take advantage of government subsidy programs.

Sustainability is firmly embedded in corporate philosophy

These developments show that sustainability at Poly-clip System is not an isolated topic. It emerges from the interplay of technology, materials, and process design and is an integral part of the company’s philosophy. A key lever is the company’s production site in Hattersheim near Frankfurt/Main: over 90 percent of Poly-clip System’s suppliers are based in Germany, mostly within a radius of around 300 kilometers. This reduces transport distances while also increasing supply reliability.

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In addition, the company relies on solar energy, a fleet of electric vehicles, and digital rather than printed product documentation. Through this consistent approach, Poly-clip System creates the foundation for developing technologies that combine efficiency and sustainability in practice.

“Sustainability must be concretely measurable and economically viable for our customers. Our solutions reduce material and energy consumption while simultaneously increasing machine performance. This enables users to make their production fit for future requirements,” emphasizes Alexander Giehl, CEO of Poly-clip System.

*All images courtesy of Poly-Clip. 

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