Case Study: Mauser Packaging Solutions
Transforming IBC scrapping, rebottling, and reporting through full digital automation.
Executive Summary
Mauser Packaging Solutions, a global leader in industrial packaging, partnered with ATK to digitise their IBC scrapping and rebottling operations. Before ATK, the workflow relied entirely on manual clipboards, handwritten notes, digital cameras, and admin staff manually creating customer reports.
In 2024 alone, Mauser processed 7,324 IBC scrapping records. ATK eliminated manual data capture, photo matching, and report creation — saving over 2,441 labour hours per year and reducing reporting turnaround from days to minutes.
The Old Process
Before ATK, IBC scrapping relied entirely on manual workflows:
- Operators walked the yard with a clipboard
- Handwrote every IBC scrapping record
- Took two photos per IBC using a digital camera
- Delivered paperwork + camera to admin staff
- Admin manually matched photos to records
- Admin manually created Word reports for customers
- Reports were emailed manually, often with delays
This process consumed thousands of hours per year and introduced errors, delays, and operational bottlenecks.
The Digital Transformation
ATK replaced the entire manual workflow with a fully digital, automated system:
- Operators capture IBC data directly in ATK
- Photos are taken inside the app and auto-linked
- No manual matching of photos to records
- No Word documents — reports auto-generate instantly
- No admin intervention required
- Customers receive digital reports immediately
What previously took days now takes minutes — with perfect accuracy and full traceability.
Time Savings Analysis
Total IBC scrapping records (2024): 7,324
Old Process
~21 minutes per IBC
Total: 2,563 hours per year
ATK Digital Process
~1 minute per IBC
Total: 122 hours per year
Total Time Saved: 2,441 hours per year
Equivalent to 305 working days — more than 1.5 full-time roles freed up.
Financial Impact
Estimated labour cost saved: ~R330,000 per year
Additional value from:
- Error reduction
- Faster customer turnaround
- Improved traceability
- Reduced admin backlog
- Better audit readiness
- Zero photo mismatches
- Zero manual reporting
Total operational value is estimated at 2–3× the direct labour savings.
Compliance Improvements
Alongside operational optimisation, Mauser also adopted ATK’s compliance modules, eliminating paper-based HSE documentation, training records, and audit preparation. This reduced compliance admin time, improved traceability, and ensured consistent safety documentation across all sites.
While not included in the core ROI calculation, compliance digitisation contributes additional operational value and reduces risk exposure.
Conclusion
ATK transformed Mauser’s IBC scrapping and rebottling operations from a fully manual, labour-intensive workflow into a fast, accurate, digital system. With over 7,000 IBCs processed annually, ATK saves Mauser more than 2,441 hours of labour per year, eliminates reporting delays, and delivers perfect traceability for customers.
For packaging and recycling operations seeking efficiency, accuracy, and digital transformation, ATK is a proven long-term solution.
