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Reusable plastic cores: when reuse really pays

ROLL Lab · app 5 of 7 · Prof: instant verdict, full report by email · updated 24 October 2026

In shortWith a core at 3.5 times cardboard and a return costing 20% of cardboard, at least 76% of cores must come back (about 4 trips per core on average). Below that threshold, one-way cardboard costs less.

Does reuse pay?Reuse is a promise until you do the sums. Give me prices, returns and the cost of the trip: I’ll tell you after how many trips plastic breaks even.

cost per use

Plastic price (× cardboard) Share returned each trip Return cost (% of cardboard)

Average uses per core

Saving per use

Minimum return to break even

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How the calculation works

The calculation assumes a loop in steady state, in which every core lost or scrapped at inspection is replaced with a new one.

Cost per trip with plastic: Pp × (1 − t) + Cr × t, where Pp is the plastic core price, t the return rate (share of cores that come back and are reusable) and Cr the cost of one return.
Cost per trip with cardboard: Pc, the price of a one-way cardboard core.
Break-even return rate: t* = (Pp − Pc) ÷ (Pp − Cr).
Average trips per core: 1 ÷ (1 − t).

The return cost must include collection, return packaging, transport, inspection, washing and administration. Cores scrapped at inspection count as lost.

Limits: it does not consider the initial cost of the core pool, the residual value of scrapped cores, the avoided disposal cost of cardboard, or differing environmental fees and taxes. The return rate must be measured, not estimated. ROLL Lab estimate.

Frequently asked questions

What return rate is needed for reuse to pay?

It depends on the price ratio and the return cost. With plastic at 3 times cardboard and returns at 20%, about 71%; at 4 times and returns at 30%, about 81% (ROLL Lab analysis).

What goes into the return cost?

Collection at the customer, return packaging, transport, inspection, washing, trimming if needed, administration. Scrapped cores count as lost.

How many trips does a core make on average?

With a return rate t, on average 1 ÷ (1 − t) trips: with 80% returns about 5 trips, with 90% about 10.

Sources

NS Packaging, plastic core reuse case (2009)
Fiaptech technical documentation, Smart Book “Which core?” (a company with corporate ties to ROLL)
ROLL Lab analysis

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