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Kedvezmenyezetti infoblokk - Szechenyi 2020 GINOP
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Інформаційний блок бенефіціара - Szechenyi 2020 GINOP

Returnable Packaging

Durable packaging systems designed for years of repeated use, for regular shipments within Europe.

Returnable packaging pays off when parts move regularly between two companies within Europe and the packaging stays in circulation for several years. The initial investment is higher, but operating costs are minimal: the packaging is durable, washable and can be reused a hundred times or more.

When Is Returnable Packaging the Right Choice?

Regular Shipments

Parts move continuously between two plants, so the packaging circulates back and forth for years.

Within Europe

The transport distance makes economical return viable, typically within the EU.

High-Value Parts

High-value or fragile components, where enhanced product protection matters most.

Environmental Impact

Returnable packaging significantly reduces waste and your packaging footprint.

Typical Solutions

Thick-walled thermoformed trays

2-6 mm wall thickness in ABS, HIPS or PP. Extreme durability, 100+ cycles.

Corrugated plastic inserts

Light, durable, washable inserts for plastic crates or containers.

Plastic crates and inserts

A returnable system: a standard plastic crate with a custom insert. The insert can be replaced while the crate stays in service.

Single-Use vs. Returnable: How to Decide

CriterionSingle-useReturnable
Unit priceLowHigher (investment)
Life cycle costHigher (ongoing)Lower (100+ cycles)
Product protectionAdequateExcellent
Environmental impactMore wasteMinimal waste
LogisticsSimple (no return transport)Collection required
Ideal distanceOverseas, long distanceWithin Europe

Design

We design our returnable packaging in CATIA V5, taking into account product dimensions, the logistics unit (pallet, container) and the transport route. During design we optimise pallet utilisation and transport efficiency.
1Requirements
2CATIA V5 design
3Prototype
4Tool manufacturing
5Pilot run
6Series production

Planning a returnable packaging system?

We will help you decide whether a single-use or returnable solution pays off better in your case.

Request a quote

How Does a Returnable System Work?

Returnable packaging is primarily economical for regular shipments within Europe, where the packaging material circulates between two companies for several years. Plastic crates, thermoformed trays and corrugated plastic materials form the basis of the system.

Higher initial investment

At the start of the project, tooling and the first production run cost more than a single-use solution. But this is an investment.

Minimal operating cost

Once the system is running, it requires little more than regular cleaning. The unit packaging cost is a fraction of the single-use equivalent.

Types of Returnable System

Plastic crate and tray

A thermoformed tray in a KLT or custom crate. The standard solution in the automotive industry.

Corrugated plastic system

Light, foldable, durable corrugated plastic boxes and inserts, reducing weight in transport.

Steel container

Steel containers with custom inserts for larger and heavier products. Details →