Schoeller Arca Systems

Packaging & logistics

Evolution of returnable materials handling solutions

Over the past two decades, the automotive industry has switched over from using disposable packaging to reusable plastic storage boxes and metal packaging instead.  This reduces costs and suits the just-in-time, lean manufacturing required of the industry today.

The automotive industry takes its environmental responsibilities very seriously and has made great efforts to become a waste packaging free environment.  For this reason, it has pioneered the use of returnable transit packaging, probably more so than any other industry.  Plastic storage boxes used in packaging for the automotive industry are generally oil-based, either polypropylene or polyethylene and are 100% recyclable.

Many automotive companies use components from many countries.  An efficient supply chain requires not only secure parts delivery from also economical return of the empty containers.  Returnable transit packaging has been developed to meet specific logistical/component types. It is designed to enable the quick and efficient movement of parts and return to the original source to keep the chain moving. With this in sight, organisations (such as Odette, VDA and Galia) have been set up to create standard packaging solutions, such as plastic storage boxes, which can work in a pool system.

Returnable packaging has proven itself cost effective, clean and easy to handle. More importantly, it works well in the whole supply chain from raw material to finished product. Gradually, the design of returnable packaging has evolved to include plastic storage boxes and foldable systems which save transport costs on return journeys, and lead to generate more efficient use of space on the assembly line.  Plastic storage boxes can be nested for return shipment, therefore taking up less space and reducing transport costs.

Numerous returnable solutions that suit the automotive industry including small foldable plastic storage boxes and bulk boxes – with various footprints to meet the different requirements of transport, assembly, warehouse and storage.  Special packaging to protect the parts using vacuum formed trays, textile dunnage systems, and foam trays cut and designed to give the part 100% protection.


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