Whitepaper: Reuse of Corrugated Cardboard Packaging
Prefer a summary? Check out the blog: The impact of reusing cardboard boxes
LET’S WORK TOGETHER FOR SUSTAINABILITY
Prefer a summary? Check out the blog: The impact of reusing cardboard boxes
LET’S WORK TOGETHER FOR SUSTAINABILITY
The story of reuse has long been central to RENUBOX. It was clear that reuse is significantly more sustainable than producing new cardboard boxes. But we wanted to go even deeper.
On this page you can read our complete whitepaper, bringing together research and making the story concrete.
Corrugated cardboard packaging is among the most widely used packaging formats in European logistics. It has become a strategic lever for cost efficiency, regulatory compliance, and environmental performance. Within this context, corrugated cardboard, long valued for its recyclability, is entering a new phase: reuse.
Reusable corrugated cardboard packaging represents a decisive shift from linear consumption to circular value creation. Rather than producing a new box for each shipment, the same box is deployed multiple times across the value chain. This significantly reduces cost per use, CO₂ emissions, and resource intensity.
RENUBOX enables this transformation. By combining reusable corrugated cardboard with operational circulation capabilities, RENUBOX turns conventional packaging into a managed, reusable asset, ready for scaling across the European market.
Reusing corrugated cardboard is not about a stronger box. It is a system innovation.
Het verwijst naar golfkarton dozen die door hun ontwerp inherent geschikt zijn om meerdere verzendcycli te doorlopen voordat ze worden recycled, ondersteund door een gestructureerd systeem van retourname, inspectie en her-distributie. Dit onderscheid is cruciaal. Hergebruik is niet toevallig; het is doelgericht, technisch ontworpen en commercieel beheerd.
Traditionally, corrugated cardboard packaging delivers value once and then exits the system. With reuse, the boxes remain in circulation. Each additional use extracts more value from the same material input, transforming the packaging from a consumable item into a circulating asset.
RENUBOX operationalises this model. It ensures that boxes are not only theoretically reusable, but are actually collected, redeployed, and integrated into supply chains with minimal intervention. No complex deposit systems are required.
Broader literature confirms this conclusion. Hidalgo-Carvajal et al. (2023) confirm that return logistics and standardisation are the two most important success factors for cardboard reuse in practice.
Unlike many sustainability reports, this RENUBOX whitepaper does not present generic international figures, but verifiable calculations for Europe. All savings are based on the European industry standard (FEFCO European Database for Corrugated Board Life Cycle Studies, 2023) and proprietary return logistics data. Below is the full substantiation per category.
The production of new corrugated cardboard emits 491 kg CO₂ per tonne, or 0.49 kg CO₂ per kilogram of cardboard. This is the 'cradle-to-gate' footprint established by FEFCO for the European industry, validated by Ifeu Heidelberg and compliant with the Greenhouse Gas Protocol.
From this figure, we honestly deduct the transport emissions of our own return journey. We do not rely on a general industry average, but on the actual fuel consumption of our own fleet: an average of 25 litres per 100 kilometres (0.25 litres of diesel per kilometre), measured across both loaded and empty trips. A return trip of 400 km therefore consumes 100 litres of diesel. Applying the official diesel emission factor of 2.646 kg CO₂ per litre (Rijkswaterstaat & Stichting Stimular, 2025), this trip produces 265 kg CO₂. At a load rate of 4,000 boxes per trip and an average box weight of 480 grams (1,920 kg of cardboard in total), this equates to 0.14 kg CO₂ per kilogram of cardboard.
Net CO₂ savings per kg of reused cardboard: 0.49 − 0.14 = 0.35 kg CO₂
Per average Renubox box (480g): 0.168 kg CO₂ saved
European corrugated cardboard factories withdraw an average of 14.1 litres of water per kilogram of cardboard produced (FEFCO & CCB, 2023). Of this water, 12.11 litres is returned to nature after purification. Only the 1.99 litres that actually evaporate or are absorbed into the product are considered net extracted.
This is the most honest measurement method: water that flows back cleanly into a river should not ecologically be claimed as ‘consumed water’.
Net water savings per kg of reused cardboard: 1.99 litres
Per average Renubox box (480g): 0.96 litres saved
European corrugated cardboard consists on average of 88–89% recovered paper. Only 11.5% consists of virgin wood fibre. This translates to a wood consumption of 0.1726 kg dry wood per kilogram of cardboard (FEFCO, 2023, ‘Total Wood’ factor).
Based on a dry matter ratio of 45% (in accordance with FEFCO) and an average European pulpwood tree of 225 kg fresh weight (FAO, 2020), this yields the following savings:
The total fuel input for European production of new corrugated cardboard amounts to 5.77 GJ per tonne of cardboard (FEFCO, 2023). Converted, this yields an energy footprint of 1.60 kWh per kilogram of new cardboard (based on the standard conversion factor 1 kWh = 3.6 MJ).
Energy savings per kg of reused cardboard: 1.60 kWh - 0.52 kWh = 1.08 kWh
Per average Renubox box (480g): 0.52 kWh saved
Every avoided kilogram of CO₂ has a measurable value for society. This value is expressed as the CO₂ shadow price: the amount society pays for the damage that one kilogram of CO₂ causes to the climate and environment.
This amount represents what your savings are worth to society: the bill that is not passed on to the next generation.
The table below summarises the full savings at three levels.
* Social value based on CE Delft CO₂ shadow price € 0.160/kg (2026 price level, indexed from Table 33, Environmental Pricing Handbook 2023). The weight of 480 grams per box is based on the average box weight of orders processed by RENUBOX.
International comparisons of packaging sustainability are regularly hampered by the use of American research data in a European context. This leads to a significant overestimation of the environmental savings.
The table below shows the key differences between the European reality (as measured by FEFCO) and the American benchmarks (Ketkale & Simske, 2023):
* Social value based on CE Delft CO₂ shadow price € 0.160/kg (2026 price level, indexed from Table 33, Environmental Pricing Handbook 2023). The weight of 480 grams per box is based on the average box weight of orders processed by RENUBOX.
Through decades of investment in recycling infrastructure, the European corrugated cardboard sector has developed one of the most efficient production systems in the world. This translates directly into lower but more reliable sustainability figures.
RENUBOX deliberately chooses the European FEFCO data. Not because the American figures are unusable, but because honesty is the foundation of credibility.
Reuse of corrugated cardboard fundamentally changes the economics of packaging. Instead of purchasing a new box for each shipment, companies reduce the effective cost per unit through multiple applications across different value chains.
This reduces the effective cost per unit and decreases exposure to raw material price volatility. In controlled systems, it also enables secondary value streams through reuse cycles and optimised asset utilisation.
Importantly, this is not a theoretical advantage. Life cycle cost modelling shows that reuse systems can deliver positive economic outcomes even under conservative assumptions. In optimised B2B environments, the cost advantage becomes even more compelling.
European packaging regulations are evolving rapidly. The Packaging and Packaging Waste Regulation (PPWR) is expected to prioritise reuse, waste prevention, and circularity at an unprecedented level.
Reusable corrugated cardboard packaging directly aligns with this. It enables companies to:
Crucially, this is achieved without abandoning the trusted material of corrugated cardboard. This makes it one of the most practical and scalable pathways to regulatory compliance.
For companies under pressure to achieve Scope 3 reductions, reused corrugated cardboard offers a ready-made solution with verifiable, externally substantiated figures. The saving of 0.35 kg CO₂ per kilogram of reused cardboard is directly applicable in sustainability reporting.
The production of corrugated cardboard is resource-intensive, particularly in the manufacture of containerboard. By extending the lifespan of each box, reuse reduces demand for:
This creates a broader sustainability benefit that goes beyond the CO₂ footprint alone, and supports corporate goals around ESG reporting and Scope 3 reduction targets.
Consumers are showing a growing preference for sustainable packaging. European consumers are leading the way:
The combination of the Renubox model and this consumer attitude offers companies an opportunity to make their strategic sustainability direction visible and credible.
One of the most powerful advantages of the Renubox model is its accessibility.
Reuse of corrugated cardboard does not require companies to overhaul their entire operation. No new machines, new materials, or complex system redesigns are needed. Existing packaging processes remain largely unchanged.
This enables companies to quickly adopt reuse, test it under real conditions, and scale it without major upfront investments. In a market where operational disruption is often the biggest barrier to innovation, this is a decisive advantage.
The deployment of used corrugated cardboard packaging yields the best results when applied in the right operational context.
Volume plays a critical role. Systems become most efficient at a scale of more than 10,000 units, where return logistics and circulation can be optimised. Below this level, handling and transport costs may have a greater impact on overall performance.
Standardisation is equally important. Reuse performs best when boxes follow consistent formats that enable simple sorting, stacking, and redeployment. Renubox provides a constant flow of the same used, sorted, and palletised packaging.
The deployment of used corrugated cardboard packaging is not an incremental improvement. It is a new standard for how corrugated cardboard can function in a circular economy.
The opportunity is clear. Cardboard boxes can evolve from disposable packaging into high-value, reusable assets with the potential to significantly reduce your packaging costs.
RENUBOX enables this evolution. RENUBOX transforms corrugated cardboard packaging into a system that delivers both ecological and commercial value.
The transition to reusable corrugated cardboard is already well underway. The question is no longer whether reuse will be part of the packaging landscape, but how quickly and effectively it will be implemented.
RENUBOX invites forward-thinking companies to take the next step:
Together we can redefine corrugated cardboard packaging: not as waste to be managed, but as value to be multiplied.
FEFCO. (2022). The carbon footprint of corrugated packaging 2021. Brussels: European Federation of Corrugated Board Manufacturers. https://www.fefco.org/circular-by-nature/ecodesign
FEFCO & CCB. (2023). European Database for Corrugated Board Life Cycle Studies 2023. Brussels: European Federation of Corrugated Board Manufacturers. https://www.fefco.org/lca/data
FAO. (2020). Global Forest Resources Assessment 2020: Main report. Rome: Food and Agriculture Organization of the United Nations. https://www.fao.org/forest-resources-assessment
Hidalgo-Carvajal, D., Gutierrez-Franco, E., Mejia-Argueta, C., & Suntura-Escobar, H. (2023). Out of the box: Exploring cardboard returnability in nanostore supply chains. Sustainability, 15(10), 7804.
Rijkswaterstaat & Stichting Stimular. (2025). CO₂ emission factors: Fuels for vehicles and vessels. https://co2emissiefactoren.nl/factoren/2025/9/brandstoffen-voertuigen-en-schepen/
RVO. (2024). Dutch energy carrier list, version January 2024. Netherlands Enterprise Agency. https://www.rvo.nl/sites/default/files/2024-02/Nederlandse-energiedragerlijst-versie-januari-2024.pdf
Ketkale, H., & Simske, S. (2023). A lifecycle analysis and economic cost analysis of corrugated cardboard box reuse and recycling in the United States. Resources, 12(2), 22.
Trivium Packaging & Euromonitor International. (2023). 2023 Buying Green Report. https://buyinggreen.triviumpackaging.com
Pro Carton. (2024). European Consumer Packaging Perceptions Study 2024. European Association of Carton and Cartonboard Manufacturers. https://www.procarton.com/consumers-across-europe-place-climate-change-as-their-number-one-concern/
Proprietary RENUBOX company data: return trip 400 km, truck (0.8 kg CO₂/km), load rate 4,000 boxes per trip, average box weight 480 grams.
Manon Schuurmans
Managing Director Renubox
Van de Velde Packaging Group
Dr. Igor Popovic
Wood savings per kg of reused cardboard: 0.1726 kg dry wood (= 0.3835 kg fresh wood)
Trees saved per kg of reused cardboard: 0.0017 trees
Per average Renubox box (480g): 0.00082 trees saved
Per 1,000 reused boxes: 0.82 trees
As with the CO₂ footprint, we honestly deduct the energy of our own return trip here. We calculate using the actual consumption of our fleet: an average of 25 litres per 100 kilometres (0.25 litres of diesel per kilometre). A return trip of 400 km therefore consumes 100 litres of diesel. At an energy content of 10.0 kWh per litre of diesel, this amounts to 1,000 kWh of energy per return trip. At a load rate of 4,000 boxes per trip (1,920 kg of cardboard), the transport energy thus amounts to 0.52 kWh per kilogram of cardboard.
RENUBOX applies the central value from the CE Delft Environmental Pricing Handbook 2023 (version 1.1, April 2025), commissioned by the Dutch Ministry of Infrastructure and Water Management. The base price of € 130 per tonne of CO₂ (2021 price level) has been indexed to 2026 using the growth factor of 4.3% per year stated in the handbook:
€ 130 × (1.043)⁵ = € 160 per ton CO₂ = € 0.160 per kg CO₂
Social value per kg of reused cardboard: 0.35 kg CO₂ × € 0.160 = € 0.056
Per average Renubox box (480g): € 0.027 social value
Per 1,000 reused boxes: € 27.00 social value
Finally, reuse depends on logistics. The success of any reuse system is determined by how effectively boxes are returned, inspected, and redistributed. RENUBOX directly addresses these challenges by providing the infrastructure and operational model needed to make reuse work reliably and at scale. This is not a limitation of corrugated cardboard; it is a characteristic of all reuse models. The difference lies in how well the system is designed.
It delivers measurable and verifiable savings in CO₂, water, energy, and raw materials, substantiated with European industry data and corrected for RENUBOX’s own transport footprint. It aligns with European market regulations. And it does so without requiring companies to give up the materials and processes they already trust.
CE Delft. (2025). Environmental Pricing Handbook 2023: Methodological basis for unit rates used for valuation of emissions and environmental impacts (Version 1.1, Publication number 23.220175.034). Commissioned by the Dutch Ministry of Infrastructure and Water Management. https://www.ce.nl/milieuprijzen
