How Logoplaste Reduced Safety Incidents by 90%
Logoplaste is a global leader in sustainable rigid plastic packaging, operating across 66 plants in 17 countries on three continents, with 86% of sites located directly on customer premises - a “wall-to-wall” manufacturing model that eliminates logistics waste and strengthens partnerships.
Company Profile
Rigid Plastic Packaging
Logoplaste Elst B.V.
Europe (Netherlands)
600 million units
Logoplaste’s Results with Poka
Accident reduction
Incident reduction
Fewer customer NCRs (Non-Conformance Report)
PPM (Parts Per Million) reduction
Faster onboarding
Reduction in voluntary turnover
The Challenge: A Wall-to-Wall Model Needing a Unified Digital Backbone
Logoplaste is a global leader in sustainable rigid plastic packaging, operating across 66 plants in 17 countries on three continents, with 86% of sites located directly on customer premises - a “wall-to-wall” manufacturing model that eliminates logistics waste and strengthens partnerships.
At its Elst, Netherlands plant, the team produces recycled PET bottles and preforms for ketchup and sauce lines. Despite advanced manufacturing capabilities, processes were still fragmented across Excel files, SAP systems and SharePoint.
“We weren’t prehistoric - but we were managing quality, safety and training across too many tools. We needed a platform that could connect everyone, not just managers,” said Petra Novakova, Plant Manager.
The goal: unify operations, engage employees through gamification, and replace paper-based systems with digital tools accessible to all workers - even those unfamiliar with Excel or email.
One Platform, Gamified for Everyone
“We wanted something that looked like a game - intuitive, visual, and rewarding. That’s how we got our entire workforce engaged,” Novakova explained.
Logoplaste implemented Poka in 2021 across its Dutch sites in Elst and Zoetermeer. Over the next three years, the company digitized all processes - from quality control to onboarding - on a single platform. Their transformation focused on three key priorities:
- Accelerated time-to-competence for new hires
- Digital learning content with automated exams and progress tracking
- Multilingual training materials accessible via QR code on any tablet
- Proactive digital safety checks and automated issue notifications
- Real-time validation and accountability
- Traceability for every task and deviation
- Standardized work instructions with multimedia
- Integrated audits and visualized forms replacing spreadsheets
- Real-time feedback loops ensuring process repeatability
Case Study 1: Safety & Quality - From Manual to Predictive
Before Poka, safety and quality processes relied on Excel-based forms and manual validations. Reporting was slow, traceability limited, and accountability diffused.
With Poka checklists and issue management, Logoplaste introduced:
- Instant digital reporting with automated alerts
- Visualized checklists with photo and video guidance
- Automatic validator notifications for completed tasks
Results:
- 100% accident reduction
- 90% incident reduction
- 81.5% fewer customer NCRs (26 down to 5/year)
- 99.8% drop in PPMs
- Immediate traceability and stronger ownership culture
“With paper, we never knew who did what. Now, every checklist is signed and validated. People feel accountable - and proud,” said Niyoma Reddy, QHSE Manager.
Case Study 2: Compliance - Building a Unified Management System
Logoplaste Elst operates under ISO 45001 (H&S), FSSC 22000 (Food Safety), and ISO 9001 (Quality Management), which demand full traceability and strict document control.
Before Poka, audits meant sifting through folders and outdated SharePoint files.
Now, all operational records are centralized and continuously updated, with automatic alerts for document review and validation.
Key Impacts:
- Managers now own their processes instead of relying solely on Quality teams
- Easy evidence retrieval during audits
- Automatic alerts for document revisions ensure compliance currency
- Reduction in audit nonconformities and stronger certification standing
“Poka made audits simple. Auditors see evidence immediately - every procedure, every record, all in one place,” Reddy said.
Case Study 3: Engagement & Onboarding - Turning Change into Culture
Following a company-wide reorganization in 2021, Logoplaste faced high voluntary turnover (32%) and low morale. The introduction of Poka became a key retention and engagement tool.
Before:
- Only 30% of staff had access to email
- Communication relied on shared inboxes and printed notices
- No visibility into employee skills or progress
After:
- 100% staff connected through Poka
- 460 factory feeds per year (vs. 0 previously)
- Voluntary turnover reduced to 5.1%
- Onboarding time cut by 40%
- Skills endorsement matrix introduced for training and performance-based bonuses
“We brought communication to the shop floor. People like, comment, and compete - it’s like Facebook for factories,” Novakova said.
With paper, we never knew who did what. Now, every checklist is signed and validated. People feel accountable and proud.
Niyoma Reddy
QHSE Manager, Logoplaste
A Digitally Engaged, Safer, and Smarter Workforce
“Poka didn’t just transform our processes - it rebuilt trust, connection, and pride,” said Novakova.
AI and Sustainability at the Core
Logoplaste’s next step is integrating AI and data analytics into its daily operations. The roadmap includes:
- Predictive maintenance: early fault detection and reduced downtime
- AI-driven quality assurance: Power BI dashboards inside Poka for real-time analytics
- Workforce assistance: digital dashboards guiding daily tasks
- Sustainable impact: monitoring energy use to reduce emissions and waste
The company’s 57,843 digital forms has saved:
- 578,000 liters of water (annual drinking needs for 800+ people)
- 289 kg of CO₂ (equivalent to 2,300 km driven)
- 6 - 7 trees annually - enough oxygen for 12–14 people
“It’s not just digital transformation - it’s sustainability in action,” said Reddy.
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