Discover your next big idea at PACK EXPO Las Vegas this September
Experience a breakthrough in packaging & processing and transform your business with solutions from 2,300 suppliers spanning all industries.
REGISTER NOW & SAVE

How To Re-use Corrugated Shippers 20 Times

Two Australian manufacturers are trialing an innovative system for the return and reuse of corrugated cases.

Box Latch 1 Wire Harnesses

On the sending side of the trial is Wiring Solutions Plus of Underdale, which makes wiring looms (also known as a wire harness, wiring harness, or cable assembly). On the receiving side is REDARC Electronics, which makes a range of electronic voltage converters, inverters, power supplies, battery chargers, brake controllers, and trailer braking products—in other words, products that require wiring looms made by WSP.

WSP ships thousands of corrugated cases of wiring looms to REDARC annually. In the past, the cases were taped closed. When REDARC received them, the tape was cut off with knives and all four top flaps were also cut off to facilitate ease of access to the components inside. The flaps and the cases were then disposed of. Not only is this procedure labor intensive and suboptimal from a sustainable packaging standpoint, it also poses the real risk of personnel lacerating themselves as they cut the tape and flaps.

In the ongoing trial, instead of taping the cases closed, WSP will close them with Box LatchTM products. These are durable injection molded devices from Box Latch Products  that are anchored to case flaps to make it possible to securely close corrugated cases for transfer from WSP to REDARC. At REDARC, the top flaps are easily opened and the contents removed. When a case is empty, an operator opens the bottom flaps, collapses the case, and stacks the collapsed cases so that both cases and latches can be returned to WSP to be used all over again.This is how the reusable corrugated cases are closed and stacked for shipment from WSP to the customer participating in the trial.This is how the reusable corrugated cases are closed and stacked for shipment from WSP to the customer participating in the trial.

Due to the uneven spread of weight in the single-wall cartons, WSP is trying two Box Latch™ Large on the bottom and one on the top to temporarily close the cases for shipping. Early testing at the WSP facilities by Phil Southam of KHP Business Solutions, the Australian Associate and Sales Representative for Box Latch™ Products, indicates two latches will hold the 11 kg weight in the current cases. “If WSP’s pilot program works as expected, it is likely WSP will move to double-wall corrugated cases to provide more strength, longevity, and security,” says Southam. More durable cases will cost a bit more but will prove to be cost-effective in the long run as well as reducing the need for two  Box Latches™ on the bottom.

List: Digitalization Companies From PACK EXPO
Looking for CPG-focused digital transformation solutions? Download our editor-curated list from PACK EXPO featuring top companies offering warehouse management, ERP, digital twin, and MES software with supply chain visibility and analytics capabilities—all tailored specifically for CPG operations.
Download Now
List: Digitalization Companies From PACK EXPO
Annual Outlook Report: Workforce
Hiring remains a major challenge in packaging, with 78% struggling to fill unskilled roles and 84% lacking experienced workers. As automation grows, companies must rethink hiring and training. Download the full report for key insights.
Download Now
Annual Outlook Report: Workforce