Elevating performance in the sky
Airline catering trolleys are essential units used by cabin crew to store, transport, and serve meals and beverages to passengers during a flight. Because they are constantly moved through narrow aisles and loaded in and out of galleys, they must be incredibly durable yet light enough to handle easily.
In the aviation industry, every kilogram of weight saved translates directly into operational efficiency and environmental benefit. Across entire fleets, every reduction in CO2 emissions per flight deliver meaningful long-term results. Driessen, with a gold medal from EcoVadis for sustainability, sought to push the boundaries of what was possible for inflight operations.
Engineering the next generation trolley
To achieve the goal of creating the world's lightest certified trolley, Diab Engineering Services worked closely with Driessen to identify the optimal foam core candidate. The material needed to provide exceptional strength and meet strict operational requirements while significantly lowering the overall weight.
By leveraging our global footprint, Diab supplied the lightest PVC foam available on the market – approximately 35 kg per m3 – from a plant close to Driessen’s operations. This local sourcing further reduced the CO2 footprint of the final product.
The Hybrite Ultra Lite: 14.1 kg of innovation
The collaboration resulted in the Hybrite Ultra Lite, weighing in at just 14.1 kg for a full-size trolley. Fully DOA and ETSO approved, the trolley reflects Driessen’s heritage of trusted engineering combined with Diab’s material innovation.
The benefits for airline customers include:
● Reduced CO2 emissions through significant weight reduction.
● Improved operational efficiency with smoother handling and service-friendly components.
"Every extra kilo in the galley means higher fuel consumption and activity."
– Jerry van Vive, former CEO of Driessen.
