Waste reduction at Safelite® (Belron®), USA


Unipacks for warm applied high viscous adhesives for car windshields.


Replacement of aluminum cartridges with unipacks for Automotive Aftermarket customer Safelite® (Belron®) to reduce packaging waste.


  • Designed equipment to modify customer’s mobile ovens (which are heated through the vehicle’s coolant system) to accept the longer unipacks
  • Developed comprehensive instructional videos and written processes to educate technicians on the proper methods for modifying guns and ovens
  • Optimized design of SikaTack ASAP+ unipack size to 465 ml to accommodate 97% of all automotive glass replacement jobs
  • Sika TM’s dispersed during Safelite rollout to assist technicians transition to unipack material
  • Installation of a new unipack packaging line at Sika’s Lyndhurst (NJ) plant to accommodate the increased volume of unipack


Significant improvements could be realized to help Safelite achieve their sustainability targets:

  • The idealized unipack size approach will reduce the annual packaging waste by 164 tons, helping to fulfill Safelite’s green initiatives
  • A pallet of unipacks fills a garbage bag while a pallet of cartridges fills a dumpster
  • Full conversion of the service fleet (4000 vans) and application equipment to unipacks
  • In addition to the packaging savings above by use of an idealized unipack Safelite will realize more than 170 tons of polyurethane waste savings