Packaging & Recycling Playbook

A complete operational framework for packaging, recycling, and IBC processing — built from real‑world experience with Mauser Packaging Solutions since 2015.

Efficiency, Accuracy, and Compliance Drive Profitability

Packaging and recycling operations rely on predictable workflows, accurate reporting, and strict compliance. IBC scrapping, rebottling, and container processing require precision — and manual systems create delays, errors, and massive admin overhead.

This playbook is built from over a decade of experience working with Mauser Packaging Solutions, transforming their IBC scrapping workflow from clipboards and cameras into a fully digital, automated system that saves thousands of hours per year.

Daily Operator Workflows

Digital IBC Scrapping Workflow

Operators capture scrapping details digitally — no clipboards, no manual notes, no camera roll sorting. Every record is timestamped, validated, and instantly synced.

Photo Evidence Capture

Operators take photos directly inside ATK, automatically linked to each scrapping record. No more SD cards, no more manual matching, no more lost images.

Rebottling & Processing Logs

Every rebottling action is logged digitally, ensuring full traceability and compliance with customer and regulatory requirements.

Operator Compliance Checks

Daily checks ensure operators follow correct scrapping and cleaning procedures, reducing contamination risk and improving output quality.

Production & Scrapping Efficiency

  • Track scrapping counts per operator and per shift
  • Monitor rebottling throughput and processing speed
  • Identify bottlenecks in cleaning, drying, and inspection
  • Use digital timestamps to measure cycle time
  • Analyse output trends to optimise staffing and workflow

Mauser’s digital transformation with ATK resulted in thousands of hours saved annually and dramatically improved reporting accuracy.

Reporting Automation

Before ATK, Mauser staff manually created Word reports for every scrapping record — matching photos from digital cameras to handwritten notes. This was slow, error‑prone, and extremely costly.

  • Automatic report generation for every IBC scrapped
  • Photos automatically linked to each record
  • No manual admin, no document formatting, no human error
  • Instant customer‑ready PDF reports
  • Full audit trail for every container processed

In 2024 alone, Mauser processed 7,324 IBC scrapping records — all automatically reported through ATK, saving thousands of admin hours.

Breakdown Reduction Framework

  • Plan services 24 intervals ahead for washers, dryers, conveyors, and presses
  • Use fluid sampling to detect early wear in pumps and motors
  • Track technician response times to reduce downtime
  • Analyse breakdown trends by machine and fault type
  • Implement operator compliance to reduce misuse
  • Review weekly breakdown reports to identify recurring issues

Packaging facilities using ATK typically reduce breakdowns by 20–30%.

Compliance & Safety

  • Digital SOPs for scrapping, cleaning, drying, and rebottling
  • Daily HSE checks with automatic alerts
  • Audit‑ready documentation stored in ATK’s Asset Hub
  • Incident reporting with photo and video evidence
  • Tracking of operator certifications and training
  • Compliance dashboards for supervisors and managers

Strong compliance reduces risk, improves quality, and protects customer relationships.

Key KPIs for Packaging & Recycling

  • IBC scrapping throughput per shift
  • Rebottling cycle time
  • Operator compliance score
  • Machine downtime per month
  • Sampling alerts per 100 hours
  • Report accuracy and turnaround time
  • Customer audit readiness

ATK tracks these KPIs automatically, giving packaging teams a clear view of operational performance.

Need a Custom Packaging Playbook?

We can tailor this playbook to your scrapping workflow, equipment types, and customer reporting requirements.

Request Custom Playbook
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