Reusable Transport Packaging Directory
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Authors: Kenneth Brown, David Van Hattum Graphic Design, Illustration: Paul Andre, Scott Andre 520 Lafayette Road, Second Floor • St. Paul, MN 55155-4100 612-296-3417 • 800-657-3843 February 1994 Reprinted October 1995 Cover : Recycled paper / 100% post-consumer content Inside pages: Recycled paper / 15% post-consumer content 3 Contents: Introduction . 6 Bags . 9 Boxes . 10 Bins. 13 Totes . 15 Pails . 18 Drums. 19 Containers for liquids . 21 Palletized containers . 23 Pallets and pallet reconditioning . 28 Slip sheets. 31 Racks . 32 Cushioning . 33 Support services for reuse . 36 Alternative shipping products . 37 Glossary . 38 Application for listing . 39 t Quick Reference Chart . 40 5 Transport Packaging The number of calls to the Office of Environmental containers means maintenance and purchasing departments Assistance (OEA) from businesses seeking information on can also realize savings. efficient transport packaging more than tripled in one year. More and more businesses are seeking information on The most typical problem is finding a manufacturer to make efficient transport packaging. Here are three examples of reusable containers that meet specific needs. This companies that sought information and then put that directory’s goal is to help make that search a little easier. information into action. Packaging Universal Hospital Services, Inc. Packaging is necessary. Damaged products squander Universal Hospital Services (UHS) rents medical equipment such as aspirators used to aid breathing. These delicate, resources and money and generate waste. Packaging helps precise instruments were being shipped out of Minnesota’s assure that products arrive undamaged and that they can be transported and handled efficiently. Some packaging, distribution center in single-use corrugated containers with loose-fill cushioning. Because these products are sensitive, however, does this better than other packaging. shipping damage was high, but a cost-effective alternative Packaging makes up about one-third of our municipal solid was unknown. waste. Approximately half of this waste comes from After researching the problem, UHS purchased 182 reusable transport packaging (USEPA). Since 1960, the total amount corrugated plastic containers with custom foam padding. of packaging waste Americans generate has increased by 85 percent (City of San Francisco). In contrast, both Japan and Product damage decreased so significantly that the reusable containers paid for themselves in less than two months. the European Community appear to generate at least one- Customers also appreciate the ease of returning the product fourth less packaging waste than we do (U.S. Congressional Service). Recent legislative initiatives in Europe place the to UHS in the reusable container. burden of packaging collection and disposal costs on In addition to cost savings in avoided damages, these manufacturers, wholesalers and retailers. These initiatives containers prevent more than 1,200 pounds of waste a year. have brought on an array of new packaging designs and The waste from an average of 1,100 single-use boxes each services to meet what is viewed as an emerging world year is now avoided. The Pack-Lite containers are expected market for cost-effective, source-reduced, recyclable and to last at least 10 years. In that time, UHS’s cost-effective reusable packaging. decision to go reusable will prevent their need to manage more than six tons of waste. The cost of managing Minnesota’s 939,000 tons of packaging waste in 1992 was between $170 million and Dataserv, Inc. $260 million (OEA). Responding to environmental, economic Dataserv, Inc., in Chanhassen, Minnesota, reuses corrugated and public pressures, the Minnesota Legislature set a goal paper boxes to ship circuit boards. In one division, the same to cut the amount of packaging going into the garbage by at boxes are reused three times; in another, they are reused least 25 percent per person between 1992 and 1995. twice. Reusing boxes saves Dataserv more than $26,000 a year in purchase costs. Reusing custom foam cushioning Businesses are responding to these pressures as well. saves the company another $17,775 a year when compared Businesses that have discovered opportunities for reusable to single-use cushioning. Dataserv’s total savings from packaging report that in addition to the environmental reusing transport packaging is almost $44,000 a year, and benefits of reducing waste, there are often economic this action eliminates over a ton and a half of waste. benefits as well. The money spent by a business to manage waste is money that is not available for other needs. Waste Toro Company disposal costs, the cost per shipped product and costs due The Toro Company manufactures lawn and turf care to damage often decrease when durable, reusable shipping products for home and commercial use. In 1990, the containers are used. In addition, the decrease in material Mound, Minnesota, facility began a major shift to reusable handling and the ordering and stocking of single-use shipping containers. The program started through cooperation with one supplier. Over time, nine suppliers 6 joined the program. Reasons cited for the change to habits die hard. Common questions to ask are: Does the reusable packaging include environmental benefits, more container assemble and collapse without tools? When efficient use of space and avoided disposal costs. collapsed, what is its return ratio (full-to-empty shipping volume)? Does it clean and stack easily? Research showed that Toro would pay essentially the same price for durable, reusable corrugated containers as they 5. Determine actual cost and waste benefits. Because of paid for single-use containers. However, the reusable reuse, fewer containers will be needed. How long will it corrugated containers eliminated more than 64,000 pounds take the reusable containers to pay for themselves? How of transport packaging, resulting in a $4,000 annual savings much solid waste will be eliminated, reducing disposal in disposal costs. costs? What work-load reductions will occur for the purchasing, stocking and maintenance departments? As Toro also implemented a returnable pallet program damage decreases, how will this affect costs? In addition, eliminating more than 74,000 pounds of waste and saving better working relationships occur with vendors, and approximately $4,600 a year in disposal costs for pallets. community environmental concerns are reduced. The total savings for reusable shipping containers is $8,600 and prevents almost 70 tons of waste each year. 6. Implement the change one product at a time. Handling costs will go down. Assembly workers will find reusable Is reuse right for me? packaging easier to use. Transportation people will see the benefits of standardized containers. Data processing Many companies have found that reusable transport staff members will discover tracking the containers isn’t packaging works for them. But how can you determine if it the horror they thought it might be. works for your company? 7. Follow-up. Changes can often uncover old problems. David Koenck, a packing professional working in Burnsville, Make sure information you give to the staff about the Minnesota, has consulted with companies about reusable change is accurate so that problems can be addressed at containers for eight years and during that time has learned their sources. If you’ve researched well, talked to about both benefits and pitfalls of reuse. According to his everyone affected several times, listened hard and chosen experience, common benefits include cost savings, less a good container company, chances are waste will waste, improved vendor/manufacturer relationships, less decrease and profits will increase. product damage and increased worker satisfaction. However, before these benefits are reaped, some work must be done. These points are meant to give some general steps to help Mr. Koenck outlined seven steps for success. implement the use of reusable transport packaging. Please contact the Minnesota Office of Environmental Assistance 1. You must be able to develop a closed-loop shipping about any points you feel need particular emphasis for future system. Opportunities may exist within the plant or with publications. outside suppliers or both. To find them, everyone from forklift drivers to the company president needs to be aware of the benefits of reuse. Get input from every area Acknowledgements of the company. Gathering the information for this directory was a cooperative process. In response to a request from the Office 2. Take a hard look at your assembly line. Can portable of Environmental Assistance, the Institute of Packaging “Just In Time” returnable racks or containers be used? Professionals and publications including Packaging Digest, What type of reusable container would work best to Packaging Magazine, Green Packaging 2000 and Good protect, transport and present the parts? Can the same Packaging published notices asking manufacturers to send container be used more than once in the assembly information on reusable transport packaging to the OEA. process? Clyde Witt of Materials Handling Engineering published a full 3. Involve your parts suppliers. Demonstrate how the page editorial on the subject. The manufacturers listed in returnable container program will cut their material this directory read these articles and sent their product purchasing and handling costs as well as reducing information to the OEA. packaging inventory and product damage. A returnable container supplier