Circular processes
Waste management
DAF is continuously working to reduce the amount of packaging material that arrives with parts at the production facilities. In a ‘war on waste’ awareness campaign, the company’s procurement team, and factory workers are encouraged to engage with suppliers to cut down on unnecessary packaging. For that reason, the focus is on reusable packaging. Components are loaded into a tailored DAF-designed return packaging at the supplier’s premises
For years, DAF has a policy to support zero waste to landfill. Residual waste that cannot be recycled is incinerated to generate electricity. At our production sites, we have our own recycling stations that collect over 100 different types of materials from concrete and cardboard to plastics, wood and metal. Different waste collectors and treatment partners process and sell these materials for reuse or recycling.
In 2025 several improvements have been implemented to further reduce disposable waste:
- In Westerlo, the cab plant for the prior vehicle generation was dismantled. A cascading system was applied to minimize waste and avoid sending usable material to general waste streams. Every machine, material, product, and installation was carefully inspected to identify possibilities for reuse, either in the new cab plant, or in other current or future projects. When reuse within the cab plant was not possible, other production sites such as Eindhoven, Leyland and even Brazil were invited to look for opportunities for reuse. Next, materials were offered for external reuse, such as being sold to partners or donated to schools and universities for training purposes. In case no new destination was available colleagues were given the opportunity to buy parts for private use, ensuring that nothing went to waste unnecessarily;
- In 2025 surplus engines, gearboxes, and axles were donated to local schools for hands-on learning, and surplus cabins to fire brigades for emergency training to support education and community safety while promoting circularity and reducing waste;
- Packaging material from incoming parts at the DAF Eindhoven production site is reused to protect large components during shipments to the assembly sites in Australia and Taiwan as well as European customers. Packaging materials such as plastic bags, cardboard sheets, foam blocks, wooden separators, one-way pallets and collars are now reused instead of recycled. Also, nearby customers return engine pallets so they can be reused in future shipments.
- To reduce packaging waste, around 95% of the inbound parts to our production plants are shipped in return packaging; after using the parts, the packaging is sent back to the supplier to be refilled. Many of these racks often face extreme conditions, leading to damage or wear. To address this, we have redesigned these racks by attaching wear parts, making them easy to remove and replace. This approach allows for quick repairs and part renewals, extending the lifespan of the packaging. Additionally, the rack can be reused for different products in the future. This innovation enhances durability, lowers costs, and promotes sustainable use of materials throughout our supply chain.
PACCAR Parts continues its packaging roadmap
During the development of new packaging to send spare parts to dealers, the key focus is always on sustainable solutions. Can we use less material, can we use recycled materials, is the material used easy to recycle? In line with these strategies, PACCAR Parts focused on multiple initiatives in 2025:
- Switching materials. For several packaging, PACCAR Parts has moved from heavy wood-based solutions to more sustainable cardboard (recycled) alternatives. This shift reduces the overall weight of packaging, lowering transportation emissions, costs and (raw) material consumption while maintaining product protection.
- Improving recyclability. PACCAR Parts redesigned their plastic bags by removing inked printing, which increases the recyclability of the bags and reduces contamination. Using single-material packaging and clear labeling further enhances recyclability and customer involvement.
- Regulations. PACCAR Parts supports compliance with regulations on reducing the use of single-use plastics, increasing the use of recycled content, and meeting mandatory targets for waste reduction. Additionally, new labeling requirements with clear recycling instructions are being introduced. PACCAR Parts is fully committed to support all applicable regulations.
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