A Comparative Life Cycle Assessment of Conventional and Reusable Packaging Systems Under Alternative Logistic Configurations

Packaging plays a crucial role in product preservation and distribution but also constitutes a major source of environmental burden. In the beverage sector, where unit value is low, secondary and tertiary packaging significantly influence the environmental profile of the final product. This study quantifies the environmental trade-offs between conventional single-use and reusable packaging systems for aluminum cans, identifying the operational thresholds that justify a transition to circular models. A standardized Life Cycle Assessment (LCA) approach is applied to five packaging configurations: three current market scenarios and two alternative solutions based on reusable plastic crates (RPCs). System boundaries include production, distribution, end-of-life, and, where applicable, reverse logistics. A functional unit of one fully packaged 0.33 L aluminum can is adopted. Results reveal that while single-use cardboard solutions achieve favorable performance under certain impact categories, reusable systems outperform them when a sufficient number of reuse cycles is achieved and reverse logistics are efficiently managed. Sensitivity analyses highlight the critical influence of transport distances and reuse frequency on overall impacts, with performance deteriorating for reusable systems beyond 200 km or below 50 reuse cycles. These findings offer concrete, evidence-based guidance for supply-chain and logistics decision-makers to optimize packaging choices and distribution network design. The study also provides robust quantitative insights for policymakers and industry stakeholders by defining the precise operational conditions under which reusable systems deliver real environmental benefits. By presenting a comprehensive, system-level comparison of complete packaging systems, this research closes a critical gap in LCA studies and sets out a practical pathway for implementing circular, low-impact packaging strategies consistent with emerging EU regulations.