Circular logistics as the backbone: Building a closed-loop system step by step

In many organizations, sustainability and efficiency are still too often treated as two separate goals. At AQUALEX, however, they go hand in hand in day-to-day operations. The Belgian specialist in drinking water systems demonstrates how logistics can evolve into a strategic pillar supporting both operational performance and sustainability goals. In collaboration with Plastibac, a circular system has been developed over the past few years that is now deeply embedded in the organization.

The foundation for this was laid by a seemingly simple decision: the switch to standardized Euro-norm containers. No more loose packaging or ad-hoc solutions, but a single, uniform container for internal storage, transport, and transfers between locations. The impact of this extends beyond just order in the warehouse. The uniformity ensures smooth operations, less handling, and a significant reduction in waste streams.

This approach was extended to the intricate logistics process. For smaller components, AQUALEX introduced storage bins that support the picking process and speed up installation preparation. Especially in an environment where products consist of hundreds of parts, maintaining an overview is not a luxury but a prerequisite for quality.

At the right moment

This is particularly true for the company’s own products. The AQUALEX Fino and Duo faucets are developed and assembled entirely in-house in Deerlijk, in collaboration with custom manufacturing partner WAAK. The complexity of this assembly process places high demands on logistics and organization. Every component must be available at the right time, in the right configuration, and undamaged. Plastibac’s storage and transport cases play a key role in this by providing structure and protection throughout the entire process.

The next step in the system’s development demonstrates how logistics and sustainability can reinforce each other. AQUALEX expanded the concept with sturdy lidded cases made from recycled plastic, featuring custom printing. These cases are filled in the warehouse, accompany technicians to the customer, and are returned after installation. This creates a closed loop in which packaging material is no longer waste, but a permanent part of the operation.

According to product manager Robbe Vangheluwe, this approach aligns seamlessly with the company’s broader vision. The ambition to have everyone drinking tap water by 2030 translates not only into product development, but also into material use and logistics. Reusability and durability are not an afterthought here, but a fundamental principle. The choice of recycled plastics and a system that remains continuously in circulation underscores this.

Collaborative design

For Plastibac, too, this collaboration illustrates how logistics solutions are evolving. Whereas the focus used to be on delivering individual products, it is now shifting toward the joint design of systems. In this case, a system that not only functions efficiently but also contributes to a lower environmental impact and a consistent approach across multiple locations and teams.

What this case study makes particularly clear is that circular logistics is rarely the result of a single major intervention. Rather, it emerges through a series of well-considered steps, each building on a solid foundation. From Euro-standard containers to specialized transport cases, from internal optimization to a closed-loop supply chain that extends all the way to the customer.

In this way, AQUALEX demonstrates that circularity doesn’t have to remain an abstract concept. It becomes tangible on the shop floor, visible in the warehouse, and noticeable in day-to-day operations—precisely where logistics makes a difference.