Cardboard boxes have been a mainstay across supply chains and logistics operations for decades. You’ll very rarely visit a warehouse, a production line or a distribution centre without seeing them. Cardboard is cheap and easy to source, however, as supply chains become more complex, the need for more sophisticated packaging has also grown, writes Dan Starnes, Sales Director at goplasticpallets.com.
Today, automation is more common, hygiene requirements are tighter and sustainability targets are harder to ignore. Supply chain professionals are under increasing pressure to reduce waste, protect their products better and keep operations running more efficiently at all times. This is why we continue to see more customers switching to reusable small plastic boxes and containers.
In demanding environments, the strength of your boxes is absolutely key. Small plastic boxes provide much greater structural strength than their cardboard counterparts. Their rigid walls and reinforced bases allow higher stacking without compromising stability. While cardboard boxes can be stacked, they are far less reliable. It is vital they are assembled perfectly to avoid malfunctions, while too much weight or uneven pressure could cause crushing and boxes to topple over. The ability to stack plastic boxes higher offers a number of advantages, including making better use of vertical space and increased safety when stored in racking systems.
Automated warehouses also benefit from this consistency. Robotics and conveyor systems depend on containers that maintain shape and dimensions. Cardboard deforms under load, which can interrupt automated handling processes.
It comes as no great surprise that cardboard performs poorly in damp environments. Once exposed to any moisture, it begins to lose strength. The material softens, warps and can eventually tear or collapse under weight. Plastic boxes are water-resistant, which is crucial in chilled distribution centres and food processing facilities where condensation is common. Meanwhile, a cardboard box will shed fibres into the surrounding environment, which is avoided with plastic.
While high-quality cardboard boxes aren’t necessarily described as single-use products, they degrade quickly – especially when opened, closed and moved frequently. In contrast, reusable small plastic boxes are designed for repeated use over many years, surviving thousands of cycles and trips. Despite the higher upfront cost, plastic will therefore deliver a better long-term ROI.
They are also a better choice from a sustainability perspective. Unlike cardboard, they don’t contribute to deforestation. Plastic boxes can be used for up to and beyond 10 years, and at the end of their working life, they can be recycled into new products. In 2019, we launched our own recycling scheme and we’ve since taken full responsibility for recycling all plastic pallets and boxes we supply. To date, we have recycled 2,700 tonnes, and we’re incredibly proud of this feat.
When it comes to cost, we admit that the upfront cost of plastic boxes is higher, but the “cost per use” will drop sharply across the lifespan of the container – also saving the hassle of constantly ordering new cardboard boxes. In fact, many of our clients are still using the same plastic boxes we supplied to them well over a decade later.
Over recent years, we have continued to add to our comprehensive range of plastic boxes, covering all shapes, sizes and features – all designed to complement any logistical operation. This includes: Euro plastic boxes, GoSmartEuro boxes, open fronted picking containers, attached lid containers, folding boxes, stack and nesting boxes, bale arm crates and ESD containers.
As supply chains become more complex, intricate and demanding, the material handling solutions used across different operations must also be fit for purpose – and small plastic boxes offer numerous distinct advantages over cardboard boxes.
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