Per-tote breakdown
| Line item | Estimate | Basis |
|---|---|---|
| Virgin HDPE resin (42 kg / tote) | ≈ 78 kg CO₂e | Embodied emissions of HDPE resin. Ref: PlasticsEurope, 2020. |
| Galvanized steel cage (28 kg) | ≈ 62 kg CO₂e | Primary steel + galvanization process. Ref: worldsteel LCI, 2021. |
| Composite pallet (wood or steel, 18 kg) | ≈ 14 kg CO₂e | Mixed material average, Southeast US sourcing. |
| Valve + fittings (brass / poly) | ≈ 8 kg CO₂e | Small parts, average composition. |
| Manufacture assembly energy | ≈ 32 kg CO₂e | Factory grid mix, TX / LA average. |
| Freight, factory → distributor | ≈ 72 kg CO₂e | Diesel truck, 1,100 mi average to Carolinas. |
| Sub-total: new 275-gal IBC | ≈ 266–330 kg CO₂e | Depending on options and freight distance. |
| Reconditioned tote: wash + test + label | ≈ 18 kg CO₂e | Our closed-loop wash water recovers ~94%. |
| Reconditioned tote: return freight (avg) | ≈ 14 kg CO₂e | Avg delivery inside our matched-route radius. |
| Sub-total: reconditioned tote | ≈ 32 kg CO₂e | Roughly 10% of a new tote. |
| Rebottled tote: new HDPE bottle | ≈ 78 kg CO₂e | Same resin impact as new, but only for the bottle. |
| Rebottled tote: cage reuse + assembly | ≈ 28 kg CO₂e | Straighten + new gaskets + test. |
| Rebottled tote: freight | ≈ 14 kg CO₂e | Same matched-route avg. |
| Sub-total: rebottled tote | ≈ 120 kg CO₂e | Roughly 40% of a new tote. |
How we roll up to the ledger
For each loop (reuse, rebottle, rework, recycle) we apply the per-tote delta against our running count of totes processed in that loop. For 2020–2026 the cumulative numbers are:
- Reused: 19,840 totes × avg 270 kg CO₂e savings ≈ 5,357 tons
- Rebottled: 4,212 totes × avg 180 kg CO₂e savings ≈ 758 tons
- Reworked (fab): 2,108 totes × avg 240 kg CO₂e savings ≈ 505 tons
- Recycled: 1,321 totes × avg 200 kg CO₂e savings ≈ 264 tons
- Additional avoided transport & handling: ≈ 1,641 tons
- Total: ≈ 8,525 tons CO₂e avoided
What this number isn't
It isn't a claim that we personally sequestered 8,525 tons of carbon. It's a claim that our activity caused 8,525 tons of CO₂e not to be emitted — because a reused tote displaces a new tote.
It also isn't a net-zero claim. Our own yard, trucks, and equipment emit real carbon. We haven't published those yet (we're working on it), but they're well under the avoided number.
Sources and caveats
- HDPE resin impact: PlasticsEurope Eco-Profile for HDPE, 2020.
- Steel cage impact: worldsteel LCI data for galvanized steel, 2021.
- Freight impact: EPA SmartWay truck emissions factor, 2024.
- Wash water recovery: measured at our facility via flow metering.
- Pallet impact: regional average, mixed wood / steel / composite.
Peer review wanted
If you're a sustainability professional and you'd like to audit our methodology, we'd love that. Email us — we'll send you the full working spreadsheet. We publish corrections prominently.
Additional line items: the full picture
The table above covers the major line items, but a complete lifecycle analysis includes several secondary factors. Here are the additional items we track:
| Line item | Estimate | Basis |
|---|---|---|
| Zinc for galvanization (2.5 kg per cage) | ≈ 12 kg CO₂e | Zinc production energy, ILZRO data 2019. |
| Water consumption for new IBC mfg | ≈ 60 gal | Factory water use for molding, cooling, testing. NAPCOR 2020. |
| Water consumption for reconditioning | ≈ 35 gal | Our closed-loop wash system measurement, net of reclamation. |
| Wash water treatment (our facility) | ≈ 0.8 kg CO₂e | Pumping + carbon filtration + pH adjustment energy. |
| Caustic detergent production | ≈ 1.2 kg CO₂e | NaOH-based detergent, per-tote consumption rate. |
| Label printing and application | ≈ 0.3 kg CO₂e | Negligible but we track it — printer energy + label stock. |
| Valve replacement (per tote) | ≈ 2.1 kg CO₂e | Brass or poly valve body manufacturing impact. |
| Gasket replacement (per tote) | ≈ 0.4 kg CO₂e | Viton or EPDM gasket manufacturing impact. |
| Electric tug (intra-yard transport) | ≈ 0.2 kg CO₂e | Grid electricity for EV charging, per-tote share. |
| Solar offset (our rooftop PV) | ≈ -1.8 kg CO₂e | Credit for avoided grid electricity, 22 kW system, per-tote share. |
| Drop-trailer diesel (avg delivery) | ≈ 14 kg CO₂e | EPA SmartWay factor, per-tote share of avg delivery distance. |
| Box truck diesel (local delivery) | ≈ 4.2 kg CO₂e | EPA SmartWay factor for medium truck, avg local route. |
| End-of-life recycling energy (HDPE grind) | ≈ 8.5 kg CO₂e | Shredder + granulator electricity, per-bottle. |
| End-of-life recycling energy (steel shred) | ≈ 3.2 kg CO₂e | Hydraulic shear + baler electricity, per-cage. |
| Re-pelletization at downstream mill | ≈ 18 kg CO₂e | Estimated from HDPE pelletization energy data. Not our facility. |
| EAF steel re-melt at Cayce mill | ≈ 22 kg CO₂e | Estimated from EAF energy per ton of scrap. Not our facility. |
Sensitivity analysis: what if our assumptions are off?
Every carbon calculation has assumptions. Here is how our total changes if key assumptions shift by ±20%:
| Assumption | Base case | -20% | +20% | Impact on total |
|---|---|---|---|---|
| HDPE resin emission factor | 1.86 kg CO₂e/kg | 1.49 | 2.23 | ±9.8% on new-tote baseline |
| Steel cage emission factor | 2.21 kg CO₂e/kg | 1.77 | 2.65 | ±6.4% on new-tote baseline |
| Avg freight distance (new tote) | 1,100 miles | 880 mi | 1,320 mi | ±4.2% on new-tote baseline |
| Wash energy per tote | 22 kWh | 17.6 kWh | 26.4 kWh | ±1.1% on reconditioned total |
| Matched-route utilization | 68% | 54% | 82% | ±3.5% on delivery carbon |
| Reuse-to-recycle split | 72% reuse / 28% other | 58% / 42% | 86% / 14% | ±12% on total avoided CO₂e |
The most sensitive assumption is the reuse-to-recycle split. If we reuse fewer totes (and recycle more), total avoided CO₂e drops by up to 12%. This reinforces why maximizing reuse — not recycling — is the core of our strategy.
Comparison with industry competitors
How does our carbon performance compare to other IBC reconditioning operations? Direct comparisons are difficult because most competitors don't publish their methodology. Here is what we can estimate:
| Metric | Charlotte IBC Totes | Large national reconditioner (est.) | Buy-new baseline |
|---|---|---|---|
| CO₂e per reconditioned tote | 32 kg | 55–75 kg | 310 kg (new) |
| Landfill rate | 0% | 5–10% (est.) | N/A |
| Wash water reclamation | 94% | 40–70% (est.) | N/A |
| Avg delivery distance | < 200 mi | 300–800 mi (est.) | 1,100 mi (factory to SE) |
| Solar offset | Yes (22 kW) | Varies | Varies |
| Published methodology | Yes (this page) | Rarely | N/A |
National reconditioner estimates are based on industry reports and our own experience with former customers of those operations. We cannot verify their internal data. The comparison is offered in good faith, not as competitive positioning.
Year-over-year progress
How our cumulative avoided emissions have grown since we started tracking:
| Year | Totes processed | CO₂e avoided (tons) | Cumulative (tons) |
|---|---|---|---|
| 2020 | 2,140 | 612 | 612 |
| 2021 | 3,480 | 1,028 | 1,640 |
| 2022 | 4,820 | 1,445 | 3,085 |
| 2023 | 5,610 | 1,680 | 4,765 |
| 2024 | 5,980 | 1,812 | 6,577 |
| 2025 | 5,451 | 1,948 | 8,525 |
| 2026 (YTD) | — | — | 8,525+ |
The increase in CO₂e avoided per tote from 2020 to 2025 reflects improvements in our reuse-to-recycle ratio (more totes going to reuse vs. recycling) and shorter average delivery distances as our matched-route program matured.
What we haven't published yet (and when we will)
- Scope 1 emissions (our trucks, gas heating): Estimated at approximately 55–65 metric tons CO₂ per year. We plan to publish a verified number by end of 2026.
- Scope 2 emissions (grid electricity): Estimated at approximately 15–20 metric tons CO₂ per year (net of solar). Also targeted for 2026 publication.
- Scope 3 emissions (upstream supply chain): We have not yet attempted to calculate Scope 3. It would include the emissions embedded in the new HDPE bottles we buy for rebottling, the diesel consumed by our carrier partners, and the emissions from downstream recycling operations. This is a 2027–2028 project.
- Water footprint: We track water consumption and reclamation operationally, but we have not yet calculated a formal water footprint per ISO 14046. Planned for 2027.