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Pitney Bowes totes reusable plastic containers

Corrugated plastic containers replace corrugated paperboard boxes for postage meter and mailing machine parts. Despite greater upfront costs, the new ‘totes’ save Pitney Bowes money by making hundreds of round trips.

At Pitney Bowes' Danbury, CT, plant, plastic corrugated totes are kept by workstations (above) where workers use them to pack in
At Pitney Bowes' Danbury, CT, plant, plastic corrugated totes are kept by workstations (above) where workers use them to pack in

The combination of economic and perceived environmental advantages recently persuaded Pitney Bowes to replace corrugated paperboard boxes with plastic corrugated containers. The company’s Danbury, CT, facility uses the “totes” to ship its injection-molded postage meter and mailing machine parts to other PB plants for final assembly.

“Pitney Bowes’ top-level management wanted to get rid of corrugated boxes to prevent them from going into dumpsters and into the waste stream,” comments Rick Beazley, the plant’s materials manager. “We were spending $100ꯠ a year or more on [paper] corrugated. If the corrugated boxes were returned, we could reuse them, but no more than about five times.”

The Stamford, CT-based maker of postage/mailing machines turned to its packaging supplier/distributor Bicknell & Fuller (Lowell, MA) for an alternative. B&F recommended that PB try plastic corrugated totes manufactured by Mills Industries (Laconia, NH). PB began using Mills’ patent-pending Milform containers in 1998, ordering 25ꯠ totes with telescoping tops.

Mills fabricates its Milform containers from 6-mm-thick corrugated sheet made by what the company refers to as a profile-extrusion process. Made from a blend of copolymer polypropylene and high-density polyethylene, the sheet then goes through thermal scoring, folding and edge welding that forms it into the Milform box or cover. Mills made the custom thermoforming machine.

A separate “die” is made for the precise dimension of each tote size. Mills earned recognition when the Institute of Packaging Professionals bestowed an AmeriStar award on the Milform process in 1999.

Round trips

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