Key Design Considerations for Bulk Reusable Packaging

Jan 23, 2025

Peninsula Plastics manufactures bulk reusable pallets, trays, and containers engineered to improve on the pitfalls of traditional packaging. Increased dynamic and static load capacities, improved ergonomics, and the ability to be personalized or standardized are benefits of large returnable packaging. These benefits are ideal for industries focused on supply chain efficiency, sustainability, and cost savings. However, before innovative packaging can be formed crucial details must be considered. By examining and implementing desired design elements, your packaging can become an integral part of your logistics system, ensuring product protection, ease of use, and long-term value.

Gauge Thickness for the Right Application

One of the first considerations in designing reusable packaging is selecting the appropriate gauge thickness for the intended application. The width of the sheet plays a part in determining the overall structural strength and flexibility. For lighter loads, a gauge thickness of .150 or less is desired, moderate weights typically require no more than .250 gauge, and for heavy units, .350 gauge will get the job done.

Light Gauge (.150 or Less)

Thinner gauge packaging is more suitable by offering a cost-effective solution by reducing material usage and overall weight, which is ideal for shipping and storing lightweight goods. On a standard pallet, this gauge can carry just under 2,000 lbs without compromising the integrity of its contents. It’s a great solution for closed-loop supply chains that ship empty packaging to and from facilities.

Medium Gauge (.250)

The next size up is a mid-range gauge that provides a little more durability and rigidity while maintaining a reduced material use for lower costs. This level of packaging is for units not exceeding 3,000 lbs and provides ample product protection. Pallets thermoformed in this gauge are perfect for average daily loads being handled within your warehouses and over the road.

Heavy Gauge (.350)

A heavy gauge is commonly used for transporting delicate or dense components that cannot be damaged from unfavorable movements along the supply chain. Due to its high tensile strength, thicker packaging allows carrying weights to reach 8,000 lbs. This is a trustworthy solution to be confident in efficiently moving your finished goods without harming them. Paired with our twin sheet forming capability, you can enhance the structural support further while allowing more design options.

Enhanced Material Handling

Understanding how goods are handled and processed from the manufacturer to the end consumer is an important part of bulk packaging design. Incorporating ergonomic features like lift assists and hand holes simplifies manual handling while improving worker comfort and productivity. For our custom part trays, our in-house design team collects the dimensions of the packaged component to ensure enough clearance for operators to comfortably grab parts individually. When integrated with automation, the same procedure occurs where precise measurements are captured to align the packaging with the movement of the computerized system. This ensures each grab, lift, or other interaction with the pallet, container, or tray is accurate each time. These features make the handling process seamless and contribute to overall operational success.

Extended Space for Warehouses and Truckloads

Maximizing space utilization within warehouses and truckloads is essential for effective and organized storage. Being a returnable solution, there must be dedicated areas to safely store them until they are loaded or shipped back. Large scale reusable packaging often incorporates stackable designs for secure and stable stacking that frees up limited room. Nestable designs are commonly seen in supply chains that experience repeat shipments back and forth. It allows the innovative design to cradle other empty packages creating an orderly stack that can move vacant packaging in sizeable quantities. Additionally, collapsible options like our sleeve packs offer a practical solution for minimizing storage requirements in warehouses and trucks. By engineering with consideration of space usage, businesses can make the most of their crucial space and streamline supply chain operations.

Balancing Standardization and Customization

Selecting between standardized or customized packaging depends on the specific requirements of your operations. Standard packaging, such as commonly used 40” x 48” pallet footprints for most industries or 45” x 48” dimensions for automotive companies has its pros. They easily integrate into established processes, offering cost-effective, time-efficient options. Since the molds are already established, the typically high upfront cost is lower with no tooling costs.

However, customized packaging provides a tailored solution for businesses with unique needs and special processes. This includes exclusive trays with built-in lift plates for heavy components, pallets with custom colors for branding, or containers with RFID tags and labels for inventory tracking and supply chain visibility. With thermoforming, customized packaging is endless and can be simple color changes or intricate designs with embedded lift plates installed.  By choosing the right level of customization, businesses can achieve optimal packaging performance without unnecessary complexity.

Ready to Optimize Your Packaging?

At Peninsula Plastics, we understand the importance of durable, efficient, and sustainable solutions. Our team of experienced designers specializes in developing and manufacturing bulk reusable packaging tailored to meet your specific needs. Whether you’re looking to reduce costs, improve handling, or increase sustainability, we can help create the perfect solution for your operations. Contact us today to get started.

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