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ORBIS Reusable Packaging & Material Handling Solutions
ORBIS manufactures reusable packaging systems designed to move products, parts, and materials repeatedly through a supply chain. Their portfolio includes plastic pallets, handheld totes and containers, collapsible bulk containers, protective dunnage, metal racks, carts, and custom reusable packaging.
At Packaging HERO, ORBIS becomes especially relevant when a customer is using large amounts of disposable packaging in a repeatable distribution loop or needs a more durable and standardized way to move products between suppliers, facilities, production lines, distribution centers, or retail locations.
Where ORBIS Fits in a Supply Chain
Many packaging materials are designed to make one trip. That can make sense when a shipment leaves the network and the packaging is unlikely to return. But when products or components repeatedly travel between known facilities, continuously replacing corrugated boxes, wood pallets, disposable dunnage, or other single-use packaging may create unnecessary cost and waste.
ORBIS focuses on reusable transport packaging designed for those repeated movements. Containers, pallets, dunnage, and racks can be selected around the product, material-handling equipment, storage requirements, transportation network, and return process.
How Packaging HERO Evaluates Reusable Packaging
Reusable packaging is not automatically the better choice simply because it can be used more than once.
We look at how frequently the packaging will travel, where it needs to return, transportation distance, product value, damage risk, storage space, pack density, handling equipment, cleaning requirements, labor, and what is being spent on the disposable packaging it may replace.
The strongest reusable-packaging applications usually have a predictable flow. When containers, pallets, or racks can be recovered and put back into service repeatedly, the economics can become very different from continually purchasing one-way packaging.
We look at how frequently the packaging will travel, where it needs to return, transportation distance, product value, damage risk, storage space, pack density, handling equipment, cleaning requirements, labor, and what is being spent on the disposable packaging it may replace.
The strongest reusable-packaging applications usually have a predictable flow. When containers, pallets, or racks can be recovered and put back into service repeatedly, the economics can become very different from continually purchasing one-way packaging.
Why Companies Consider ORBIS
Built for Repeated Use
ORBIS containers, pallets, racks, and other systems are designed for repeated movement through demanding material-handling and distribution environments rather than a single shipping cycle.
Standard & Custom Solutions
A broad portfolio of standard pallets, totes, and bulk containers is supported by custom packaging and dunnage capabilities for parts or processes that need something more specialized.
Designed Around Material Flow
Reusable packaging can be evaluated around automation, storage density, return transportation, line-side presentation, picking, assembly, and other operational requirements in addition to product protection.
Reusable Packaging Approaches with ORBIS
Reusable Plastic Pallets
Plastic pallets provide consistent dimensions and reusable construction for applications involving storage, transportation, automated material handling, manufacturing, food and beverage, retail distribution, and other supply-chain environments.
Totes & Handheld Containers
Stackable, nestable, and collapsible reusable containers can support picking, storage, assembly, processing, distribution, automated handling, and repeated movement of products or components.
Collapsible Bulk Containers
Reusable bulk containers protect larger quantities of products and components while collapsible designs can reduce the amount of space occupied when empty containers are stored or returned.
Reusable Dunnage
Fabric, foam, plastic, and engineered dunnage can separate, position, and protect individual parts inside reusable containers or racks while supporting repeatable loading and unloading.
Metal Racks & Material Handling
Reusable metal racks can transport and store larger or unusually shaped products and can be combined with protective dunnage for components that require more structure than a plastic tote or bulk container provides.
Custom Reusable Packaging
When a standard container does not fit the product or process, ORBIS can develop custom bulk containers, totes, pallets, dunnage, thermoformed packaging, foam packaging, and other application-specific solutions.
Where Reusable Packaging Makes the Most Sense
Reusable packaging is particularly attractive when products move through a closed or controlled supply chain. Examples include supplier-to-manufacturer routes, transfers between company facilities, distribution-center replenishment, manufacturing work-in-process, and other repeatable transportation lanes.
If the empty packaging can reliably return for another trip, the original investment can be spread across repeated uses. If containers frequently disappear from the network or return transportation is difficult, disposable packaging may still be the more practical choice.
The Return Trip Matters Too
A reusable container may spend part of its life moving product and another part returning empty. That return trip can have a major effect on the economics of the program.
Collapsible bulk containers and nestable or collapsible totes can reduce empty-container volume so more packaging can fit into storage areas and return transportation. The return ratio, transportation distance, and available storage space should therefore be considered when selecting the reusable packaging format.
Reusable Packaging for Automated Operations
Consistent packaging dimensions can become increasingly important as conveyors, robotic handling, automated storage and retrieval, and goods-to-person systems are introduced into a facility.
ORBIS offers pallets and containers designed for automated material-handling environments. When automation is part of the project, packaging dimensions, deck design, container geometry, deflection, load weight, sensors, conveyors, and handling equipment all need to be evaluated as part of the same system.
Reusable Packaging Still Has to Protect the Product
A durable tote or bulk container solves only part of the packaging problem if the product can still move, collide, scratch, or become damaged inside it.
Reusable dunnage can create dedicated locations for individual products or components and help maintain separation during handling and transportation. Depending on the application, that may include fabric, foam, plastic, thermoformed, or other engineered interior packaging.
The container and its interior protection should therefore be designed as one packaging system rather than selected independently.
Reusable dunnage can create dedicated locations for individual products or components and help maintain separation during handling and transportation. Depending on the application, that may include fabric, foam, plastic, thermoformed, or other engineered interior packaging.
The container and its interior protection should therefore be designed as one packaging system rather than selected independently.
Standard Container or Custom Packaging?
A standard tote, pallet, or bulk container is often the best starting point because established sizes can simplify implementation and avoid unnecessary tooling or engineering.
Custom packaging becomes more relevant when the product has unusual dimensions, requires dedicated protection, needs a particular pack quantity, must interface with automation, or needs to arrive at a production line in a specific orientation. ORBIS supports both standard products and engineered custom packaging for these more specialized applications.
Cost, Waste & Sustainability Considerations
One of the potential advantages of reusable packaging is reducing the repeated purchase and disposal of single-use packaging. But sustainability and cost should be evaluated using the complete system.
Packaging life, number of trips, product damage, pack density, cleaning, return transportation, loss rates, repair, storage, and what happens when the packaging eventually leaves service can all affect the result.
For Packaging HERO, the objective is not simply to replace disposable packaging with plastic. It is to determine whether a reusable system can perform the job effectively and make operational and financial sense over repeated use.
Packaging life, number of trips, product damage, pack density, cleaning, return transportation, loss rates, repair, storage, and what happens when the packaging eventually leaves service can all affect the result.
For Packaging HERO, the objective is not simply to replace disposable packaging with plastic. It is to determine whether a reusable system can perform the job effectively and make operational and financial sense over repeated use.
Managing a Reusable Packaging Program
The larger the reusable packaging fleet becomes, the more important it is to know where those assets are and how quickly they return.
ORBIS also supports reusable packaging management programs that can include tracking, inventory management, demand planning, reverse logistics, inspection, cleaning, refurbishment, repair, and other services designed to keep reusable assets circulating through the supply chain.
Common ORBIS Use Cases
Manufacturing & Supplier Loops
Reusable totes, bulk containers, pallets, racks, and protective dunnage can support repeated movement of components between suppliers, manufacturing plants, assembly operations, and distribution locations.
Warehouse & Automation
Consistent reusable pallets and totes can support storage, picking, conveyors, automated handling, goods-to-person systems, and other material-flow applications.
Replacing Disposable Packaging
Operations repeatedly buying corrugated containers, wood pallets, disposable dividers, or other one-way materials may evaluate whether a returnable system can reduce long-term packaging consumption.
Choosing the Right ORBIS Reusable Packaging System
The right system depends on what is being moved, how often it moves, where the packaging returns, product protection requirements, transportation method, material-handling equipment, storage space, pack density, and the expected number of trips.
Packaging HERO can help evaluate the current disposable or reusable packaging process and determine whether an ORBIS pallet, tote, bulk container, dunnage system, rack, or custom reusable packaging solution makes sense for the application.
Buying the same disposable packaging over and over for a supply chain that keeps traveling the same route? Packaging HERO can help evaluate whether ORBIS reusable pallets, containers, dunnage, racks, or custom packaging can provide a better long-term solution.
