The growing adoption of automation in warehouses and distribution centers is reshaping how customers are using reusable packaging, specifically plastic pallets and totes.
Here’s what’s driving this change and how plastic pallets and totes are evolving to meet customer needs.
Repeatable performance is driving the evolution of plastic pallets and totes
System uptime is critical for today’s companies. Food manufacturers must maintain a strong bottom line while dealing with labor shortages along with increased costs and, in some cases, even tariffs. That is where automation along supply chains can help offset these variables.
The increased need for e-commerce and omnichannel fulfillment, which requires faster and more flexible logistics, is another factor driving this evolution. Reusable packaging that is consistent in its shape and materials, like plastic pallets and totes, will enable repeatable performance in these systems and help companies reduce downtime.
Customers are seeking sustainable product solutions. As a result, product development is becoming more focused on smarter, more sustainable designs, and manufacturers are investing in material innovation. This helps improve consistency and dimensional molding tolerances to ensure the plastic pallets and totes aren’t being misread by photo eyes and robots, which would jam up systems.
Overall, plastic pallets and totes are being more purposely designed to integrate seamlessly with robotic picking, automated systems or high-speed conveyors. Customers are seeking automation-friendly design features such as:
• Slots for vertical lifting
• Dimensional consistency
• Molded-in features for robotic gripping
• Flat surfaces for labels to be read by vision systems and other readers
Designs that account for hygiene and durability
When used in automation, plastic pallets and totes need to be designed with durability and cleanliness in mind. With designs that feature reinforced corners and ribbing, a plastic pallet or tote’s lifespan can expand significantly. It is important to have smooth surfaces that help prevent snagging and misalignments when plastic pallets and totes are moving through automated systems. As an added benefit, smooth surfaces prevent debris that could halt operations like wood chips or stray nails that wood pallets can leave behind. Additionally, plastic pallets and totes are easily cleaned, making them a more hygienic and safer option for both employees and automated systems.
Maximizing space and efficiency
Companies need to factor in space constraints and operational efficiency during the design process of plastic pallets and totes to ensure solutions are both stackable and nestable, maximizing storage capacity while reducing footprint.
By optimizing space and efficiency, customers expect lower transportation costs, improve handling and keep operations running smoothly.
Using smart packaging to demonstrate ROI
Smart packaging – embedding censors or tracking technologies to monitor variables like location, temperature, usage cycles or how often plastic pallets and totes are turning within their system, will continue to play a key role.
Certain products now have RFID tags incorporated or barcodes that enable real-time tracking and inventory visibility. The more a company can reuse a plastic pallet or tote, the more life they get out of it, which increases the ROI. Having visibility to this ROI is crucial for quantifying it.
Building an automated system around plastic pallets and totes needs
To work as needed, automated systems require compatible plastic pallets and totes. For example, a company starts with an automated system and then seeks a reusable plastic solution. They can’t find one that works with their system and soon discovers the high cost of a customized solution. That’s why it’s essential for customers to first define and align their priorities, whether it’s hygiene, durability, sustainability or return on investment before selecting the right solution.
The next step is determining how incorporating a reusable plastic solution can help meet these goals.
Then, focus on building an automated system around existing reusable plastic solutions in the marketplace, in a way that’s not reinventing the wheel every time.
Future considerations
When meeting with customers, examine their own use of plastic pallets and totes and consider how reusable packaging could fit into their broader automation supply chain and sustainability strategy.
Key questions to ask include:
• Is the pallet or tote compatible with your current or future automation systems?
• Can it help reduce labor costs or improve throughput?
• Does it support food safety traceability requirements?
• Is it part of a reusable, returnable packaging program that aligns with environmental, social and governance (ESG) goals?
Partnering with a supplier who understands automation in the food manufacturing space is going to be essential for success. It’s about recognizing plastic pallets and totes as key components in building a more efficient and sustainable supply chain.
