Solution
Carton to Reusable Packaging Conversion
Move a single-trip carton line onto a returnable polypropylene loop
Corrugated plastic containers are a cost-effective alternative to corrugated cardboard boxes and cartons. The container is made of polypropylene, so it is waterproof, washable, 100% recyclable and can be reused instead of replaced on every trip.
The work is in matching the new container to the loop you already run: the pallet footprint, the stack height, the return transport and the number of trips you expect before the container is retired.
The Route We Follow
Requirement Analysis
Product weight, pallet footprint, stack height, number of trips and whether the container is washed between cycles.
Design
Box or tote drawing with divider layout, hand holes, lid and any accessories. Because the container is fabricated from sheet there is no mould fee, so geometry stays flexible.
Material Selection
Sheet thickness from 2 mm to 12 mm and weight from 250 g/m² to 2000 g/m², plus grade: standard, anti-static, conductive, UV stabilised or flame retardant.
Sampling
We submit samples for your approval before production. Samples are free of charge and sent by FedEx, UPS or DHL.
Production
Extrusion on our six lines, then cutting, creasing and fabrication to the approved sample.
Quality Control
ISO 9001:2000 system, with every product 100% tested before delivery.
Packing
Plastic shrink film and wooden pallet, or the packing method you specify.
Logistics
Sea freight through our shipping agent to any destination port, with transportation insurance arranged on your behalf if you want it.
Products Used in This Solution
Corrugated Plastic ContainersCollapsible Corrugated Plastic BoxesFoldable reusable boxes that return flat and save storage spaceView Details 
Corrugated Plastic ContainersAuto Parts Packaging ContainersReusable boxes, containers and bulk boxes without mould costView Details 
Corrugated Plastic ContainersPostal Totes and TraysColour coded totes and trays for mail and parcel handlingView Details 
Corrugated Plastic ContainersSleeve Pack Pallet ContainersTriple-wall sleeve on a thermoformed pallet and cover for bulk cargoView Details Industries Where This Applies
FAQ
FAQ About Carton to Reusable Packaging Conversion
How Do We Compare Cost Against Cartons
Compare cost per trip rather than cost per box. A corrugated plastic container is reusable and washable, so the same unit covers many cycles.
Do We Need Tooling
No. Containers are fabricated from sheet, so unlike a moulded box there is no expensive mould fee and the size stays flexible.
Can You Match Our Current Carton Footprint
Yes. The container is cut to your drawing, so it can drop into the pallet pattern you already use.
How Do I Get Samples
Samples are free of charge. We send them as soon as possible by FedEx, UPS or DHL international air express.
Get a Quotation for Carton to Reusable Packaging Conversion
Send thickness colour weight per square metre and end use and we quote against that specification
Samples are free of charge and sent by FedEx UPS or DHL · Production 7 to 10 days after order confirmation