Closed-loop box reuse

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This image depicts the closed-loop box reuse between multiple locations on the same or distant premises. BL-Loop-process-multi-site-final-wiki.jpg
This image depicts the closed-loop box reuse between multiple locations on the same or distant premises.
Reusable plastic containers for sorting and routing mail USPS sorting tubs.jpg
Reusable plastic containers for sorting and routing mail
Clips holding flaps open on conveyors during work in progress (WIP) Box Latch Clips.jpg
Clips holding flaps open on conveyors during work in progress (WIP)
Molded plastic containers for distribution, return, and reuse. Retailpallyandlid.jpg
Molded plastic containers for distribution, return, and reuse.

Closed Loop Box Reuse, is the process by which boxes or other containers are reused many times. It is a form of reusable packaging. [1]

Contents

This is sometimes suited to a large business where containers are used and reused within the location; the custody of containers stays in secure control. Business-to-business commerce also allows controlled return by reverse logistics; a “closed system” and a circular life cycle. Containers may be constructed of corrugated fiberboard, corrugated plastic, molded plastic, or other materials. Identification of containers by labels, bar codes, various colored latches or RFID chips [2] is common.

Description

Reusable corrugated box. Partial overlap box has center slots to tuck flaps loosely closed for in-plant storage or routing. When palletized and shrink wrapped, it can be used as a shipping container. Closed box juliane krug.svg
Reusable corrugated box. Partial overlap box has center slots to tuck flaps loosely closed for in-plant storage or routing. When palletized and shrink wrapped, it can be used as a shipping container.
Corrugated plastic box can be used and reused many times. Most PSA tapes can be removed without damaging the surface. PP box.jpg
Corrugated plastic box can be used and reused many times. Most PSA tapes can be removed without damaging the surface.

When closed loop supply chains [3] exist or can be created during work in process or progress, boxes are frequently opened and closed to remove and replace contents for inspections, calibration, testing, quality assurance, powder coating or other purposes. Eliminating tape during this process eliminates human injuries from box cutters, blades and knives as well as eliminating damage to box contents.

A means of closing the containers is usually needed such as lids, covers, straps, staples, tape, latches, clips, bands, Hook-and-loop fasteners, etc. When using devices that hold flaps down and out of the way, they can be stacked and stored open or moved about on carts, conveyors, trucks or pallets while remaining open. This saves time and labor while enhancing [{sustainability]} by reusing clips and undamaged boxes. It is important that these temporary means of closure and reopening does not deface or damage the cartons.

At endpoints in these single or multi-site linear or circular closed loops, the temporary closures are removed for reuse and boxes taped for secure shipping to their next or a final destination.

Alternatively, these fiberboard boxes may be collapsed with their closing devices attached and returned to the loop origin in a flattened manner. This reduces time and spares human injuries caused by cutting tape on tops and bottoms. It also lowers costs for freight and allows for speedy reconstruction of cartons in a tapeless, closed loop.

Containers can be reused dozens of times before disposal or recycling. This leverages supply chain cost savings at the same time it embraces supply chain sustainability.

History

Reuse of. boxes and other containers has been common for many years. For example, the automotive industry has long used reusable racks, totes, and boxes. [4] One type of “closed loop box reuse” was used by Jack D. and James F. Wilson, coinventors of supportive devices developed to keep cardboard box flaps closed or held open without the use of tape. [5] The closed loop term describes a circular life for boxes and cartons made possible by the help of such supportive devices.

Closed-loop box reuse is the process by which packaging materials can be used and reused to minimize waste. Similar and overlapping terms commonly used are closed-loop recycling, returnable packaging, reusable packaging, sustainable supply chains and circular economy. Laws have been passed in Maine [6] and Oregon [7] to make it the responsibility of producers of waste to pay into a fund based on the amount and the ability of the materials used in their packaging to be recycled. These funds will be employed to reimburse municipalities for eligible recycling and waste management costs, make investments in recycling infrastructure, and help citizens understand how to recycle.

A circular economy is a large-scale model that involves the sharing, leasing, reusing, repairing, refurbishing and recycling of existing material in a global environment. Reverse logistics is an alternative to a traditional linear economy (take, make, waste). [8] It seeks to reduce waste, recover resources at the end of a product's life, and channel it back into production, thus, significantly reducing pressure on the environment. Closed-loop box reuse shares similar goals and perspectives but is specific to the circular life cycle of fiberboard boxes in systems where reuse is the focus.

Environmental impact

The goal of closed-loop fiberboard box reuse is to reduce waste and pollution. The supply chain accounts for more than 90% of the environmental impact experienced by most consumer goods companies, [9] more than 800 million tons of cardboard and paper are disposed of yearly in the USA. [10] Reusing one ton of fiberboard boxes saves 390 kWh of energy, 46 gallons of oil and 700 gallons of water. [11]

Recycling (or reusing) that same ton of corrugated board produces less than 50% of sulfur-dioxide than if made from raw materials and saves more than 9 cubic yards of landfill. [11] In 2018, over 17 million tons of paper and paperboard were landfilled in the U.S. [12] It is the largest component of municipal solid waste.

Closed loop box reuse allows companies to meet their Circular Economy, ISO, Six Sigma, Lean Manufacturing or Zero Waste goals. Closed loop opportunities exist in assembly lines, pick and pack fulfillment centers, kitting operations, warehouse management systems, and moving and storage businesses.

Related Research Articles

<span class="mw-page-title-main">Corrugated fiberboard</span> Composite paper material

Corrugated fiberboard or corrugated cardboard is a type of packaging material consisting of a fluted corrugated sheet and one or two flat linerboards. It is made on "flute lamination machines" or "corrugators" and is used for making corrugated boxes. The corrugated medium sheet and the linerboard(s) are made of kraft containerboard, a paperboard material usually over 0.25 millimetres (0.01 in) thick.

<span class="mw-page-title-main">Box</span> Type of container

A box is a container used for the storage or transportation of its contents. Most boxes have flat, parallel, rectangular sides. Boxes can be very small or very large and can be used for a variety of purposes, from functional to decorative.

<span class="mw-page-title-main">Paperboard</span> Thick paper-based material

Paperboard is a thick paper-based material. While there is no rigid differentiation between paper and paperboard, paperboard is generally thicker than paper and has certain superior attributes such as foldability and rigidity. According to ISO standards, paperboard is a paper with a grammage above 250 g/m2, but there are exceptions. Paperboard can be single- or multi-ply.

<span class="mw-page-title-main">Packaging and labeling</span> Enclosure or protection of products for distribution, storage, and sale

Packaging is the science, art and technology of enclosing or protecting products for distribution, storage, sale, and use. Packaging also refers to the process of designing, evaluating, and producing packages. Packaging can be described as a coordinated system of preparing goods for transport, warehousing, logistics, sale, and end use. Packaging contains, protects, preserves, transports, informs, and sells. In many countries it is fully integrated into government, business, institutional, industrial, and personal use.

<span class="mw-page-title-main">Carton</span> Type of domestic container

A carton is a box or container usually made of liquid packaging board, paperboard and sometimes of corrugated fiberboard. Many types of cartons are used in packaging. Sometimes a carton is also called a box.

<span class="mw-page-title-main">Cardboard box</span> Type of packaging

Cardboard boxes are industrially prefabricated boxes, primarily used for packaging goods and materials. Specialists in industry seldom use the term cardboard because it does not denote a specific material. The term cardboard may refer to a variety of heavy paper-like materials, including card stock, corrugated fiberboard, and paperboard. Cardboard boxes can be readily recycled.

RockTenn was an American paper and packaging manufacturer based in Norcross, Georgia. In 2015, it merged with MeadWestvaco to form the WestRock company.

<span class="mw-page-title-main">Bulk box</span> Pallet-size shipping box

A bulk box, also known as a bulk bin, skid box, pallet box, bin box, gaylord, or octabin is a pallet-size box used for storage and shipping of bulk quantities.

<span class="mw-page-title-main">Folding carton</span> Type of paperboard packaging

The folding carton created the packaging industry as it is known today, beginning in the late 19th century. The process involves folding carton made of paperboard that is printed, laminated, cut, then folded and glued. The cartons are shipped flat to a packager, which has its own machinery to fold the carton into its final shape as a container for a product. An example of such a carton is a cereal box.

Cardboard is a generic term for a heavy-duty paper.

<span class="mw-page-title-main">Single-stream recycling</span>

Single-stream recycling refers to a system in which all paper fibers, plastics, metals, and other containers are mixed in a collection truck, instead of being sorted by the depositor into separate commodities and handled separately throughout the collection process. In single-stream, both the collection and processing systems are designed to handle this fully commingled mixture of recyclables, with materials being separated for reuse at a materials recovery facility.

<span class="mw-page-title-main">Corrugated box design</span> Process of matching design factors for corrugated fiberboard boxes

Corrugated box design is the process of matching design factors for corrugated fiberboard boxes with the functional physical, processing and end-use requirements. Packaging engineers work to meet the performance requirements of a box while controlling total costs throughout the system. Corrugated boxes are shipping containers used for transport packaging and have important functional and economic considerations.

Cardboard is a generic term for heavy paper-based products. The construction can range from a thick paper known as paperboard to corrugated fiberboard which is made of multiple plies of material. Natural cardboards can range from grey to light brown in color, depending on the specific product; dyes, pigments, printing, and coatings are available.

<span class="mw-page-title-main">Multi-pack</span> Packaging that combines or holds multiple items or smaller packages

A multi-pack also known as multipack is packaging that combines or holds multiple items or smaller packages.

<span class="mw-page-title-main">Ifco tray</span> Type of reusable packaging

IFCO trays are a type of reusable packaging for transporting fresh food produce. IFCO SYSTEMS is the name of the company that first developed a pooling service for reusable plastic trays for fresh produce in 1992, when the company was founded in Pullach, Germany. IFCO is the acronym for International Food Container Organization.

Reusable packaging is manufactured of durable materials and is specifically designed for multiple trips and extended life. A reusable package or container is "designed for reuse without impairment of its protective function." The term returnable is sometimes used interchangeably but it can also include returning packages or components for other than reuse: recycling, disposal, incineration, etc. Typically, the materials used to make returnable packaging include steel, wood, polypropylene sheets or other plastic materials.

<span class="mw-page-title-main">Plastic container</span>

Plastic containers are containers made exclusively or partially of plastic. Plastic containers are ubiquitous either as single-use or reuseable/durable plastic cups, plastic bottles, plastic bags, foam food containers, Tupperware, plastic tubes, clamshells, cosmetic containers, up to intermediate bulk containers and various types of containers made of corrugated plastic. The entire packaging industry heavily depends on plastic containers or containers with some plastic content, besides paperboard and other materials. Food storage nowadays relies mainly on plastic food storage containers.

<span class="mw-page-title-main">Shipping tube</span> Long and narrow cardboard shipping container

A shipping tube, mailing tube, or cardboard tube is a shipping container used to ship long items. It is usually a long package with a narrow cross-section: square, triangle, or round.

<span class="mw-page-title-main">Packaging waste</span> Post-use container and packing refuse

Packaging waste, the part of the waste that consists of packaging and packaging material, is a major part of the total global waste, and the major part of the packaging waste consists of single-use plastic food packaging, a hallmark of throwaway culture. Notable examples for which the need for regulation was recognized early, are "containers of liquids for human consumption", i.e. plastic bottles and the like. In Europe, the Germans top the list of packaging waste producers with more than 220 kilos of packaging per capita.

<span class="mw-page-title-main">Closed-loop recycling</span>

Closed-loop recycling is the process by which a product or material can be used and then turned into a new product indefinitely without losing its properties during the recycling process.

References

  1. Soroka, W. Illustrated Glossary of Packaging Terminology (Second ed.). Institute of Packaging Professionals. p. 185.
  2. Thoroe, P W (2009). "The impact of RFID on management of returnable containers". Electronic Markets. 19 (2–3): 115–124. doi: 10.1007/s12525-009-0013-3 . S2CID   30186368.
  3. Reynolds, Matt (October 11, 2022). "Closed-Loop Corrugated Case Reuse Process Delivers Savings Through Cycles, Material Input Reduction". packworld.com. Retrieved November 11, 2022.
  4. Akabane, G (2018), Returnable packaging as a sustainability factor in the automotive chain: a case study., vol. 6, Archives of Business Research, 6(9), 21-31., pp. 21–31, retrieved 20 September 2022
  5. Bucher, Chris (2016-12-01). "Giving Boxes a New Lease on Life". gmtoday. Retrieved 2022-02-19.
  6. "Extended Producer Responsibility Program for Packaging". Maine Department of Environmental Protection. Retrieved 2022-02-19.
  7. "Plastic Pollution and Recycling Modernization Act". Oregon.gov. 2021-08-06. Retrieved 2022-02-19.
  8. "What is Linear Economy". IGI Global. Retrieved 2022-02-19.
  9. "Supply Chains Cause 90% Of Companies' Environmental Impacts. How Can They Be Improved?". youmatter. 2019-02-19. Retrieved 2022-02-19.
  10. "Amazing Facts About Cardboard Waste & Recycling". All County Recycling. Retrieved 2022-02-22.
  11. 1 2 "Recycling Facts". Recyclingbin.com. Retrieved 2022-02-22.
  12. "Paper and Paperboard: Material-Specific Data". United States Environmental Protection Agency. 7 September 2017. Retrieved 2022-02-22.