News » 16.04.2026 - Austrian grower achieves 93% return rate with reusable tray system
When Erwin Plettig talks about the reusable tray system at his horticultural business in Stallhofen, Austria, his enthusiasm is unmistakable. "Environmental awareness and sustainability are simply part of our company's philosophy," he says. "Alongside the use of HVO diesel and recyclable pots made from post-consumer recyclate, we developed a reusable tray together with Pöppelmann TEKU® that has been very well received by our customers. They are enthusiastic, and so are we. Instead of five single-use trays, we now have a premium system and are saving enormous amounts of plastic waste."
Plettig, 35, runs the family-owned horticultural business Blumen Plettig KG in its third generation. The company supplies around 150 customers in total, including propagators, smaller florists, and an Austrian garden centre chain.
Since the first delivery of the TEKU reusable trays, single-use trays have been phased out entirely. "We said to each other: let's just do it," Erwin Plettig recalls with a laugh. "Launching in the peak season was bold, but forward-thinking." He notes that customers initially asked what the trays would cost them. The answer was straightforward: "Nothing. We just want them back."
The system has performed better than expected. Plettig has delivered more than 80,000 trays in total, and of the approximately 5,000 units still in circulation, all have been returned, bringing the return rate to over 93%.
Plettig points out that the company's own logistics operation is a significant advantage in running an in-house reusable system. Five company-owned trucks operate throughout Austria and Slovenia during the season. That said, he is confident that the benefits of the reusable tray can also add value within other collection concepts across the broader industry. Customer feedback has been consistently positive: "They are pleased to be generating less waste and making a meaningful contribution to climate protection."
That kind of feedback resonates with Dirk Moormann, Area Sales Manager at TEKU responsible for customers in the German-speaking region. He recalls the initial conversations with the Plettig family, which took place around 2022. "The company was determined to introduce a reuse system," he says. Erwin Plettig describes the collaboration: "Our practical experience and TEKU's expertise came together perfectly in the tray. That is why TEKU was the ideal partner for this project."
During product development, the TEKU team focused on finding the optimal balance between stability and weight, and quickly settled on the more material-efficient and cost-effective thermoforming process. The resulting tray is made from post-consumer recyclate (PCR), contributing to the circular economy, and weighs around 300 grams, approximately 260 grams lighter than comparable injection-moulded reusable trays on the market. "In day-to-day practice, that difference takes a considerable load off our staff," says Erwin Plettig, who also highlights the ergonomically shaped handle, which significantly improves carrying comfort.
The tray offers another key advantage in terms of standardisation. "Previously, we used five different tray formats," Plettig explains. "In our reusable system, there is now a single universal tray that can be used with various pot sizes." The tray is designed for round pots of 12 cm and 13 cm, and square pots of 11×11 cm. Drainage holes in the base make it suitable for both transport and propagation. After at least 15 cycles of use, the trays show no signs of wear. "I expect at least another 50 cycles are possible," Plettig adds.
When Erwin Plettig first discussed the idea of a commercial reuse system for plant trays with his father more than four years ago, the EU Packaging and Packaging Waste Regulation (PPWR) was not yet a factor. The sector now faces the prospect of mandatory requirements for reusable trays from 2030 onwards. Plettig sees his early adoption as a strategic advantage: "Knowledge is power. When the legislation comes into force, we will already have several years of experience behind us."
The same applies to the team at TEKU. Through the collaboration with Blumen Plettig, the company expanded its expertise in developing reusable trays via the thermoforming process. This enabled the horticultural packaging specialist, based in Lohne, Germany, to present three different universally applicable thermoformed reusable trays at IPM Essen, covering the full range of pot sizes from 8 to 13 cm. These reusable trays are available as standard from stock, suitable for use by retailers and growers alike, and can optionally be fitted with an RFID label.
Source: www.floraldaily.com
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