Ecopolplast Hits 98% On-Time Delivery and Powers DPPs with Zebra RFID

Ecopolplast, a Polish manufacturer transforming recycled plastics and post-consumer rubber into Ecoplastomer®, has digitized its warehouse operations and launched Digital Product Passports (DPPs) by deploying an end-to-end RFID tracking solution based on Zebra Technologies’ hardware.

The move replaces manual, paper-based tracking with real-time visibility across a multi-level warehouse and has helped Ecopolplast improve inventory accuracy, accelerate cycle counting, and raise on-time delivery performance to 98%.

From paper and clipboards to real-time traceability

Before adopting RFID, Ecopolplast tracked hundreds of big bags using paper forms, clipboards, and staff memory. Materials were stored across multiple levels, and locating a single bag often required repeated forklift trips. As the company expanded into more product variations, the likelihood of mixing up materials increased, creating traceability gaps and the potential for costly errors. After a major customer received the wrong material variation, Ecopolplast set out to eliminate mistakes and ensure complete, auditable tracking.

At the same time, the company was working with partners to implement Digital Product Passports, requiring granular traceability of materials through production and logistics. To support this level of transparency, Ecopolplast needed a system capable of capturing movements and inventory status automatically and in real time.

The solution: Zebra RFID across printing, fixed infrastructure, and mobility

Ecopolplast began tagging every big bag with RFID labels printed on Zebra ZT411 industrial printers. To automate tracking throughout the facility, it installed Zebra FX9600 fixed RFID readers with Zebra AN480 antennas at key locations such as receiving docks, storage aisles, and shipping areas. As tagged items move, the system records events automatically and feeds real-time location and status data into Ecopolplast’s inventory processes.

Warehouse teams also use Zebra TC26 mobile computers to scan RFID tags, conduct cycle counts, verify stock, and perform quality checks digitally, replacing paper routines with faster, more consistent workflows.

The deployment was rolled out in phases, planning, installation, and optimization, with integration and operational support from partners, followed by focused training to ensure rapid adoption on the warehouse floor.

Outcomes: measurable operational gains and DPP enablement

With RFID-enabled visibility in place, Ecopolplast reports significant improvements across warehouse performance and customer service, while creating the operational foundation required to launch Digital Product Passports:

• Digital Product Passports successfully rolled out

• Inventory accuracy increased by 15% within one month

• Cycle count time reduced by 5x (from days to roughly 1.5 hours)

• On-time delivery improved by 10%, reaching 98%

• Overall throughput increased by approximately 20%

• New customer engagement supported by CO2 emissions traceability through DPPs

Ecopolplast also reports that DPP capability strengthens customer confidence by providing evidence-backed traceability and helping differentiate its materials in sustainability-driven procurement discussions.

“The digital product passport adds a powerful layer of credibility and proof behind carbon footprint emissions of each product,” said Katarzyna Pokwicka, Founder and Chief Executive Officer at Ecopolplast. “It’s a game-changer, and we wouldn’t have been able to implement it without fully automated processes that Zebra’s RFID technology provides.”

To learn how Zebra RFID solutions can help manufacturers improve traceability, increase inventory accuracy, and digitize operations for initiatives like Digital Product Passports, connect with a Zebra specialist to discuss your deployment needs.