Totes, reusable plastic containers, bulk bins, pallets, trays and crates are commonly used throughout food manufacturing and distribution facilities. Unlike packaging that can vary in dimension or condition, reusable plastic packaging is designed to maintain consistent dimensions, surfaces and handling features through repeated use. This predictability is increasingly valuable as manufacturers implement conveyors, automated storage and retrieval systems (ASRS), robotics and machine vision systems engineered around specific tolerances and repeatable interfaces.

As automation has become increasingly sophisticated, reusable plastic packaging has evolved alongside it. Rather than viewing packaging simply as something that transports products from point A to point B, manufacturers can view it as an integral part of the automated system.

Creating a Consistent Interface

Automation performs best when variability is minimized. Reusable plastic packaging provides a consistent interface between the product and automated equipment. 

One of the unique advantages within the food industry is that the same reusable plastic packaging can potentially interact with multiple processes and automated systems throughout the supply chain. Depending on the application, reusable plastic packaging can move from the field or processing environment through manufacturing, cooling, storage and distribution and ultimately into retail and merchandising.

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This means packaging may encounter many different automation interfaces and operating environments throughout its journey. Maintaining consistent dimensions, handling features and performance through those cycles helps equipment reliably convey, identify, lift, stack, store, pick and otherwise interact with the packaging.  

Repeatability and consistency are particularly important because automated systems are engineered around defined tolerances. Reusable plastic packaging can maintain those dimensions and performance characteristics through repeated use. 

Durability and reliability are also important. Rather than continually introduce new packaging into an automated environment, manufacturers can use an asset designed to perform through many cycles, which creates both operational and financial benefits.

Taking a System-Wide Approach

Selecting reusable plastic packaging for an automated application starts with understanding the application rather than simply choosing a container or pallet. Key considerations include the product being handled, load requirements, material flow, equipment interfaces, storage environment, transportation, sanitation requirements and how the packaging will be handled throughout its entire cycle. 

Collaboration is especially important in automated applications, given packaging touches different parts of the supply chain. Working with the end customer as well as automation integrators, equipment manufacturers and all supply chain partners, can help define the requirements at each interface to determine the best solution that can perform throughout the system. 

Incorporating Technologies to Improve Operational Visibility and Asset Management 

Reusable plastic packaging creates an opportunity for the packaging itself to become a trackable asset. Depending on the application, technologies such as barcodes, RFID, Bluetooth Low Energy (BLE) and GPS can be installed on the packaging and incorporated into an asset-management strategy to provide greater visibility into where packaging is located and how it is moving through the supply chain.

That visibility can help companies better understand cycle times, dwell time, inventory levels and asset utilization, while identifying where reusable assets may be delayed or lost. In pooled or closed-loop reusable packaging systems, that information can be particularly valuable because the economics and sustainability benefits of the program depend on keeping assets moving and maximizing productive turns. 

For automated operations specifically, consistent identification locations on reusable plastic packaging also can support scanning, vision systems, readers and other automated identification technologies. Combining a durable, repeatable reusable asset with identification and tracking technologies can give manufacturers greater visibility into both their packaging fleet and the products moving through their operation.

Measuring Success

The success of reusable plastic packaging should be evaluated across operational, financial and sustainability metrics. Operationally, we look at whether the packaging performs consistently within the process, supports uptime, reduces product damage, minimizes manual intervention and moves reliably through the automated system. 

Financially, total cost of ownership is important. This can encompass packaging life, number of turns, asset loss, labor, transportation efficiencies, product damage and other costs associated with the overall system. While reusable plastic packaging typically requires a greater upfront investment than expendable packaging, its total cost of ownership can become attractive when the asset is effectively managed and reused over time. The benefits can extend to improving automation performance, reducing interruptions and minimizing product damage. Additionally, financing programs are now available and companies can bundle the packaging along with the automation equipment.

From a sustainability standpoint, reusable plastic packaging replaces single-use or expendable packaging and supports a circular model in which an asset is used repeatedly throughout its service life. The specific environmental impacts, in terms of energy and water conservation, greenhouse gas (GHG) emission reduction and solid waste prevention, depend on the application, transportation network, number of turns and how effectively the reusable asset pool is managed. 

As food manufacturers continue to automate, reusable plastic packaging has an opportunity to play a pivotal role. Its durability, consistency, repeatability and ability to be tracked can help create a predictable foundation for automated systems while supporting operational, financial and sustainability goals across the supply chain.