EDO-2024-000026

Converting to Reusable Transport Packaging
Your company has the power to make a positive impact on the environ-
ment. Companies that convert to reusable transport packaging, made of
sturdy virgin or recycled-content plastic, durable wood, or metal, are not
only reducing their waste and conserving energy and natural resources,
but are also lowering labor and material costs over time, ensuring better
product protection, and improving worker safety with ergonomically de-
signed handles and access doors.
By following these key steps, you can find out if reusable transport packaging will work for your company:
Reusable transport packaging works the best for companies that ship in closed
loop distribution systems, meaning the container and/or pallet always goes back
to the same point of origin. Although companies that ship products in a man-
aged open-loop system can use ental companies to manage the return of empty
packaging, as well as ensuring that the packaging is inspected, cleaned, and re-
paired as needed.
The following list of conditions, developed by INFORM, Inc. and the Reusable
Packaging Association (RPA), can be used to determine if reusable transport
packaging is a good choice for your company:
• Short distribution distances. Shorter distances mean lower freight
costs are incurred in hauling back containers. Shorter distances also ex-
pedite the return of containers to suppliers.
• Frequent deliveries of consistent products in large volumes. Fre-
quent deliveries of consistent products in large volumes usually mean
that inventory turns over rapidly, which makes it possible to collect emp-
ty containers with each delivery. This minimizes the number of contain-
ers in storage and transport and minimizes the supply of containers that
a company must purchase.
• Company-owned or “dedicated” vehicles. If companies involved in
shipping and receiving use company-owned vehicles, there is typically
no charge for return shipping. Producers may also work with trucking
companies that have dedicated part or all of their fleet to making deliver-
ies to or from a single customer.
Step 1: Determine if Reusable Transport Packaging Will Work for Your Company
Key Steps
Key Steps to Converting to Reusable Transport Packaging
Copyright © 2010 State of Utah | All Rights Reserved 2
Step 2: Compare Costs of One-Time vs. Reusable Transport Packaging
Follow these tips from the Reusable Packaging Association to compare the costs for one-time or limited-
use packaging with the total costs of reusable transport packaging, including any costs for reverse logis-
tics (transporting empty containers back to your facility):
1. Identify potential products. Develop a list of products that are similar in size, shape, and weight
that are frequently shipped in large volumes.
2. Estimate one-time and limited-use transport packaging costs. Estimate current costs of us-
ing one-time and limited-use packaging. Include costs to purchase, store, handle, and dispose of
the packaging.
3. Develop a geographical report. Develop a geographical report by identifying shipping and
delivery points. Evaluate the possibility of working with suppliers to make a switch to reusable
transport packaging.
4. Review reusable shipping container options and costs. Reusable transport packaging is avail-
able with various features that facilitate shipping, handling, and storage, including:
• Collapsibility: The walls of the container are designed to fold down when not in use.
• Nestability: Empty containers can be placed inside each other easily.
• Stackability: Tops and bottoms are designed to lock into one another to allow for greater
stacking heights.
Visit the Container Exchange website for examples of the various types of Gaylord boxes, totes,
and pallets that are available. Compare the prices of both new and used products.
5. Develop a preliminary cost comparison. Based on the information gathered in the previous
steps, develop a cost comparison between one-time or limited-use packaging and reusable trans-
port packaging. Consider using the Reusable Packaging Association’s model to compare the ba-
sic cost differences beteween one-time and reusable transport packaging. The model uses basic
assumptions and requires you to input various cost components, such as: the purchase price of
the containers, dwell time in days that a container will be held at various stages in the distribu-
tion chain, number of containers shipped in a given year, internal rate of return, and the number
of miles that an empty container will travel to return to your facility (return logistics).
• Small number of parties. Controlling the return of empty containers is easier when the number
of parties handling containers is small; for example, when a bakery delivers directly to a grocery
store without intermediate storage in a warehouse.
• Large or bulky products or those easily damaged. Large or bulky products, or those that are
easily damaged, require bigger, more expensive one-time or limited-use containers, so the poten-
tial for long-term cost savings is greater.
Key Steps to Converting to Reusable Transport Packaging
Copyright © 2010 State of Utah | All Rights Reserved 3
Before making a decision to convert to reusable transport packaging, check out the case studies on the
UseReusable website—a partnership between the StopWaste Partnership and the Reusable Packaging
Association—to learn more about the savings and benefits realized by companies that have converted
to reusable transport packaging. The testemonies from other companies may help streamline efforts for
making the switch to reusable transport packaging.
The following case study features a Utah company that has made the switch to reusable transport packag-
ing:
Step 3: Review Case Studies
Case Studies on Use Reusables Website:
www.usereusables.com/casestudies/index.html
Container Exchange: www.containerexchanger.com
INFORM, Inc.: www.informinc.org/xsum_deliver.php
StopWaste Partnership: www.stopwaste.org
Case Study for Autoliv
Autoliv, a worldwide leader in automotive safety, specializes in the manufacture of airbags at its Ogden
facility. The company wanted to eliminate waste, decrease the risk of product damage, and significantly
reduce other costs associated with the use of wood pallets and cardboard boxes. In 1994, Autoliv made
the switch to reusable containers using collapsible and nestable containers of all sizes. The collapsible or
stackable containers take up less space—as much as 5 to 1 density—on the return trip to the factory. To
improve efficiency, Autoliv also color codes its reusable containers, which helps conveyance personnel
identify containers.
Due to the frequent reuse of the containers, Autoliv’s return on investment (ROI) occurred within three
months. As an added benefit, with reusable containers, workers are less likely to suffer from repetitive
stress injuries associated with opening and taping cardboard boxes.
Issued February 16, 2010
State of Utah, Utah Department of Environmental Quality
168 North 1950 West, Salt Lake City, Utah 84116
Comments and Questions
Contact: DEQ Business Assistance Coordinator
Phone: [phone]
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