Plastic totes, containers and pallets

This update focuses on the latest trends in usage of this category of equipment, along with a source list of suppliers and, for the first time, their web addresses.

By Ray Kulwiec -- Modern Materials Handling, 6/1/1998

Returnability and reusability are key words in any discussion of plastic containers and load bases, whether they be totes, bulk boxes, or pallets. As more companies understand the economic advantages of a returnable container program, the trend grows. In the area of plastic products, tote boxes, bulk containers, and pallets all provide the advantages of returnability throughout the supply chain.

Auto companies have pioneered the concept of using returnable containers. A most impressive current example of benefits achieved is the Ford plant in Windsor, Ont., which has saved millions by using returnable containers and eliminating 30,000 lb of disposable packaging a day (See MMH, September 1997, p. 42).

Tote boxes are used widely for in-plant handling, but can be used for shipping and receiving with the addition of lids and locking hinges. Totes can be bar-coded or equipped with RFID tags for material control, and compartmentalized for holding different parts. For use in carousels, totes can be molded with ribbed bottoms that stabilize them and interlock with shelf wires.

Bulk containers also function well for work-in-process handling, as well as for storage and distribution of various products. Collapsible versions provide great space savings during storage or return shipping. Stackability provides another space-saving feature. Four-way forklift access is common, and drains can be provided for washing.

Plastic pallets are lightweight, durable, and feature dimensional consistency. They operate well on conveyors or other handling systems. Initial high price compared to wood is often offset by the multiple return trips they offer. Standard and customized footprint designs are available. To avoid bending while being stored in racks, pallets can be stiffened with material modification, special design, or inclusion of special inserts.

The table shows "who makes what.''

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