Reusable Transport Box: Plastics for Modern Logistics

Disposable packaging still dominates many logistics processes – often at the expense of efficiency and sustainability. A new reusable transport box aims to close this gap by conserving resources, saving costs and being flexible in use. The solution was developed by Fraunhofer LBF.

In an interview with K-Mag, Dr Christian Schütz talks about the requirements for such a reusable transport box, its advantages and the response so far.

Dr Schütz, what prompted the development of the reusable transport solution?

Dr Christian Schütz: Nowadays, cushioning and filling material consisting of plastic flakes and film, air cushioning, corrugated cardboard or wood wool is used for transport protection. Recycling the filling materials is currently not very worthwhile from a purely economic point of view, which means that modern logistics does not utilise a considerable sustainability potential. The same also applies to outer packaging, as cardboard packaging, for example, is generally only used once. In the case of material recycling, not only the considerable energy requirement, but also the transport routes for disposal and processing must be taken into account.

What were the main requirements for the transport box and how were these technically realised?

Schütz: The transport box is still under development; the current tests were carried out with a demonstrator series, for which the focus was on mechanical strength and durability as well as uncomplicated handling. At the same time, the production and choice of materials had to enable the most cost-efficient solution possible.

However, the exact properties of the reusable box have not yet been finalised: The material properties of the outer packaging and inlay as well as the dimensions, design and shape of the inlay can be customised for specific applications. We are happy to take on further functionalities so that a market-ready solution is of interest to as many users as possible.

What materials is the box made of? And how does the environment benefit from your solution?

Schütz: The boxes in the demonstrator series are made of polyethylene or polypropylene. In order to optimally support mechanical recycling in the long term, the end product should be a monomaterial solution; both polyolefins would be suitable for this.

The practical test at the UVEX SAFETY GROUP has demonstrated the efficiency of the system. What specific advantages stood out in particular?

Schütz: When using the reusable box, the work processes can be carried out just as quickly or even faster than with the previous packaging materials. It was also possible to save on additional packing or padding material and all transport items were dispatched without damage throughout the entire test. Dispensing with additional packing or cushioning material also saves space, as there is no need to keep the material on hand or to use disposal containers for used and unusable material. If the reusable boxes are not needed, they can be folded up and stored to save space.

The press release emphasises that no additional investment in shipping logistics was required. How did you achieve this and what significance does this have for potential users?

Schütz: No investment in additional hardware or equipment is required to use the boxes, apart from the portable blowers that are needed to fill the inlay. This means that switching from disposable packaging material to a solution like ours does not result in any significant additional costs. The reusable boxes are also standardised to the dimensions of Euro pallets.

What reactions did you receive from the employees who worked with the new transport boxes and how did this feedback influence the project?

Schütz: The employees from logistics were very positive about the handling of the reusable boxes: the work steps are quick and easy to learn, and the handling was perceived as uncomplicated overall. There is also no need to dispose of used disposable packaging material and the boxes are quickly available for reuse.

The consortium is looking for further development partners for individualised applications. Which sectors do you see as particularly suitable for collaboration and which customisations could be relevant?

Schütz: We are not fixed in terms of sectors and, together with our co-initiators from Berges GbR, have already held discussions with users from a wide range of industries. The spectrum of goods to be transported ranged from electronic components to consumer goods and foodstuffs. The customisations are based entirely on the individual requirements of the users and with our co-developers at Turtlebox GmbH and G&H GmbH Rothschenk we can make a great deal possible. This applies both to the material properties in the utilisation phase and to end-of-life scenarios such as closed-loop recycling.