For food and beverage manufacturers and distributors, superior product protection is the number one reason for transitioning from cardboard and wood to reusables. Sturdy, moisture-proof reusable containers have a high stacking strength and good insulating properties that protect products even in rough shipping environments. In the agricultural industry where profit margins are slim, reducing spoilage is critical. Many farming operations now use robust yet well-ventilated reusable crates to package and ship produce. Improved ventilation removes field heat faster, improving produce freshness and lowering cooling costs.

As one would expect, choosing reusable transport packaging over limited-use alternatives is better for the environment, too. And today more than ever, sustainable operations and a greener supply chain add value to a company's portfolio and appeal in the marketplace.

Research by StopWaste.org has shown that energy use, solid waste, and greenhouse gas emissions are all significantly greater for disposable packaging, even when it's recycled, compared to reusables. A 2004 life cycle study that compares reusable plastic crates to corrugated cardboard containers found that reusables produced 95 percent less solid waste, required 39 percent less energy and generated 29 percent less greenhouse gas emissions.

Because reusable containers and pallets are lighter and can be stacked more efficiently, fewer forklift trips are needed inside a facility and more product can be loaded onto each truck, reducing the number of trips. That means lower fuel costs as well as emissions -- a big concern with today's high gas and diesel prices.

Who Should Consider Reusables?

Switching to reusables can add large profits to a company's bottom line, but it also requires operational changes and up-front investment. Typically, reusable transport packaging has a higher initial cost than one-time or limited-use transport packaging because it is designed and manufactured with more durable, longer-lasting materials. Other costs may include new material handling equipment, such as washers and sanitizers, additional or new storage systems, and reverse logistics (the return transportation of empty reusables packaging components).

However, these costs are usually offset by the savings opportunities: reduced disposal and labor costs, decreased or eliminated product damage and better worker safety. The return on investment (ROI) for the higher cost of reusable packaging depends on the frequency of reuse: the more trips each reusable container or pallet can make, the higher the ROI. Operations that will generally benefit from reusables are those with a flow of consistent products in large volumes and "closed-loop" systems, where the delivery of products can be combined with the return of empty containers in one trip. Large or bulky products -- or those easily damaged -- are also good candidates for reusable transport packaging.

To help businesses determine if a switch to reusables makes sense for them, the Stopwaste Partnership, together with the Reusable Packaging Association, has developed a Reusables Cost Comparison Tool. The tool is available at www.usereusables.org, a website that addresses all aspects of reusable transport packaging. The site also includes case studies, a listing of relevant events and workshops, and many other resources.

Justin Lehrer is the program manager at StopWaste.org.