Efficiency & technology

In-house logistics: A collaboration offering many advantages

Just under half of all of ALPLA’s plants are in-house operations directly at our customers’ premises. ALPLA opened its very first in-house plant in Lomazzo, Italy, in 1985. The close proximity to the customer and the resulting contribution to climate protection have been part of ALPLA’s company philosophy for more than 35 years.
ALPLA operates one of its most state-of-the-art in-house plants in Aston Clinton, UK.

Many customers have since recognised the numerous environmental and economic advantages – less warehouse space is needed, the short routes eliminate the need for transport packaging, the staff costs are likewise lower and we can respond flexibly and quickly to production changes. What’s more, we have developed award-winning innovations thanks to our long-standing partnerships right next door to our customers. Drawing on our many years of experience, we support our customers right from the outset and are able to quickly set up our in-house operations.

In-house plants not only minimise costs and allow for close collaboration which is successful for both sides, but also result in considerable CO2e reductions.


Flagship project in Bowling Green

One of the largest and most state-of-the-art in-house plants has been in operation for Henkel in Bowling Green, Kentucky, since July 2020. A single-level production hall of more than 15,000 square metres was built in under six months for HDPE bottles to be produced there for the largest Henkel detergent plant in the world.

What makes this fully automated production line special is the warehousing system – up to 14 trays can be stacked one on top of the other. The warehouse serves as a buffer on the one hand, offering customers production reliability, and boosts planning flexibility on the other. Thanks to optimum capacity utilisation, energy consumption and the number of rejects can be reduced. Additionally, the bottles remain in an upright position from production all the way through to the bottling line. This is because the bottles are more rigid when stood upright, which allows us to reduce the bottle weight and material consumption in line with the customer’s specifications.


The key benefits of in-house plants at a glance:

  • Reduction in carbon emissions and other transport-related environmental impacts
  • Packaging production directly connected to the customer’s bottling line
  • Elimination of secondary packaging and transportation costs
  • Reduction in the outer packaging needed for shipping
  • Customised logistics solutions, automated storage
  • Minimum storage space required
  • Close collaboration promotes innovation and improvements
  • Local jobs created

In-house Production | ALPLA Group