Plastic automation totes and trays are a critical component of any automated system. They are the standard alternative to corrugated boxes that don’t convey well at high speeds and can be easily damaged, causing product loss, operational inefficiencies, and resulting in unnecessary waste.

Plastic automation totes are clean and hygienic, eliminating dust and fibers that can result from totes made from other materials, and if they become soiled, can be easily washed, and quickly returned into use. Automation totes create the uniformity required across non-uniform items to optimize handling efficiency.

But there are many different types of plastic automation totes and tote manufacturers. When totes are not well selected for their function or poorly manufactured, they can be unnecessarily expensive or perform improperly to the point of continuous system failures. Below, we’ll discuss some of the top considerations that will influence your tote selection for automated systems.

Size & Customization Options

While every automated system is unique, there are many standardized tote footprints used across a variety of automated systems. Two of the most commonly used are the 600 mm x 400 mm and 650 mm x 450 mm footprints. Within each footprint, there are different height options, typically ranging from 220 mm to 440 mm. Depending on the system and the products that need to be accommodated in the container, custom sizes may be required.

Oftentimes, tote customizations other than size are required for a specific application. For example, barcode labels that uniquely identify a tote need to be in specific locations and readable on the container so the system can accurately read it.

Optional dividers or mini tote systems offer flexibility and allow for more efficient use of a container. Depending on the product that will be inside the tote, custom material blends, such as ESD (Electrostatic Dissipative), may also need to be considered.

Specifications & Tolerances for Automated Storage & Retrieval Systems

Tote requirements for an automated system leave very little room for error. Deviation from specs, even by a millimeter, can cause totes to get hung up in the system, potentially bringing operations to a halt.

The bottom of an automation tote is also critical to its performance. It impacts how well the tote moves throughout the distribution center as well as how the items contained within the tote will be supported. The wrong bottom can also contribute to unwanted noise in a facility.

Look for Quality, Repeatable Manufacturing

AS/RS can be tough handling environments for totes, so you’ll want to work with a manufacturer that understands how to produce a durable container that will continue to perform in the system for a long time.

Reliable repeatability is paramount to the success of a manufacturer of automation containers. A quality manufacturer will be able to consistently manufacture totes within the required specifications and without deviation. This means consistency between the first tote in an order to the last, and from one order to another. That consistency also extends to predictable cycle times, resulting in accurate production schedules and on-time deliveries.

Choose Monoflo for Automation Totes

Consistent, Quality Products

Monoflo has invested in cutting-edge technology that enables us to manufacture high-pressure injection molded automation containers fast and at a lower price while still adhering to the strictest of spec tolerances.

Our ISO 9001-2015 processes and state-of-the-art technology ensure every piece that comes off the line meets these specifications for the best possible performance, order after order. And our consistency in manufacturing translates into reliable totes, delivered on time for a seamless induction.

Industry Experts

With so many options and plastic automation tote manufacturers out there, it can be a challenge to sort through the noise and decide what’s best for your application. As we help our customers navigate their tote selection, we start by understanding what their need is.

What kind of system will this tote be inducted into? What type of products will be contained in the tote?

There are several considerations that contribute to selecting the appropriate container for the job, and you’ll want an experienced product and industry expert to help you work through them all.

Whether you’re building a new facility or inducting new totes into an existing facility, our experience and relationships with system integrators enable us to deliver exactly the tote that you need within the tolerances required to ensure a seamless induction into your system. Our automation container product lines include Stack Only Containers, Collapsible Containers, and Stack & Nest Containers. For more information or to learn about our automation tote offering, get in touch with our team today.

Plastic pallets are a staple product used in warehouses and distribution supply chains across the globe. They are designed for different purposes, applications, and industries, but not all pallets are created equal. Below, we review five factors you should consider when evaluating a distribution pallet.

5 Considerations When Selecting the Right Plastic Pallets for Distribution

1. Pallet Size

Standard-sized pallets have a GMA (Grocery Manufacturers Association) 48” x 40” footprint and are used throughout the food manufacturing and distribution industries. Other common footprints include the 30” x 42”, popular for direct-to-store applications, and the European standard (EUR1) size of 1200 mm x 1000 mm.

2. Load Capacity

Load capacity is how much weight a pallet can support in a given environment. Your pallet load capacity must meet or exceed the weight of the load you plan to put on your pallet. A pallet’s load capacity is predominantly influenced by design and material and are commonly evaluated in three ways: static, dynamic, and racking.

• Static Load Capacity measures how much weight a pallet can accommodate while stationary or stacked, while sitting on a warehouse floor, for example.
• Dynamic Load Capacity measures the maximum weight that can be evenly distributed while a pallet is being lifted or moved, usually by a forklift or hand jack.
• Racking Load Capacity is the maximum distributed weight a pallet can hold while in a racking system. With a range of racking types, including supported and non-supported, how much the pallet can handle will depend on the type of racking system available at your facility. It is always best to consult with a professional salesperson to discuss the best pallet for your specific application.

3. Pallet Durability

Durability is a significant factor to consider when evaluating the right pallet for an application. Pallets that aren’t designed for heavy loads can break, potentially damaging the product they are carrying or posing a hazard to employees, impacting productivity and workplace safety. Additionally, pallets made of certain materials break more easily than other pallets. For example, structural foam pallets are brittle due to air pockets that are created during manufacturing, so they are more susceptible to breakage and failure.

4. Cleanliness

Depending on the product placed on the pallet, or the facility where the pallet is used, some pallet designs or materials are not well suited for the application. For example, facilities in food processing or pharmaceutical manufacturing must adhere to strict cleanliness requirements. Injection molded plastic pallet’s smooth, non-porous surface is resistant to pest infestation and bacteria growth, making them ideal for cleanroom applications.

5. Overall Pallet Cost

Selecting the pallet with the lowest upfront cost can be tempting, but if it falls short in areas like the ones we’ve just discussed, you may pay more in the long run. These hidden costs are often incurred in additional freight, efficiency or productivity loss, equipment or product damage, employee injuries, and replacing broken pallets. It may be worthwhile to spend more upfront for a better-performing, longer-lasting pallet that will be more cost-effective over time.

Benefits of Injection Molded Plastic Pallets for Distribution

Injection Molded Plastic pallets are well-known in the distribution industry for their light weight and extreme versatility. They offer durability, are safer, more hygienic, and have a lower cost of ownership than other options.

Durable & Strong

High-pressure injection molded pallets are more durable than many other plastic pallets on the market. They are designed to be impact resistant and can often remain in service even after impact from a fork tine. They also experience significantly less breakage than pallets made of structural foam, another commonly used material in pallet manufacturing.

Safe & Hygienic

High pressure injection molded plastic pallets are smooth and non-porous, making them resistant to microbial growth, chemical contamination, and pest infestation. Many plastic distribution pallets are also designed to be easily washed and put back into use quickly. And because plastic pallets are lightweight, won’t splinter, and don’t contain sharp metal, they are safer for employees who work with and handle them every day.

Sustainable

Plastic pallets have a much longer lifespan than pallets made from other materials. Once they reach the end of their life, they can be easily recycled for use in new products. Plastic pallets can also be manufactured using recycled material. This helps to reduce waste and ensure a more sustainable packaging system.

Cost-Effective

Injection molded plastic pallets are light weight and manufactured using less material, resulting in freight savings beginning with their first delivery. While plastic pallets may carry a higher upfront cost, it is quickly recouped for most facilities through improved operational efficiency, reduced product damage, and longer service life. Customers quickly realize the upfront investment in injection molded plastic pallets, and ROI is easily seen.

Why Monoflo for Plastic Pallets for Distribution

An Industry Leader

Monoflo’s continued investment in technology allows us to deliver a superior, more reliable pallet that sets us apart from our competition. We hand select only the best-in-class robotics and machinery to automate our manufacturing processes and optimize efficiency. This translates into cost savings that enable us to provide better performing, premium-quality pallet at a competitive price.

Industry Experts

Monoflo employs a curated team of experienced, highly-trained engineers and designers, as well as industry experts with a deep understanding of our customers’ business. Our team provides individualized attention to help our customers optimize their packaging strategy and overcome challenges they’re facing.

Wide Variety & Customization Options

Monoflo’s high-pressure injection molded pallets offer the highest strength-to-weight ratios, making them perfect for the distribution industry. Our pallet product lines include Welded and Non-Welded Nestable Pallets, as well as Rackable and Stackable Pallets.

• Nestable 48” x 40” Injection Molded Welded G2 Pallet has a two-piece welded design with enhanced internal deck ribbing that delivers strength and durability with low tare weight, offering superior handling of heavier loads.
• Nestable 48” x 40” Injection Molded Pallet This nestable plastic pallet is designed around a footprint for GMA applications. This pallet is designed for storage or shipment of distribution and retail goods, as well as high-end export needs.
• Nestable 1200 mm x 1000 mm Injection Molded Pallet is designed around an EUR 2 footprint, an international standard. It is a one-piece, high-pressure injection molded pallet, and its slightly smaller footprint lends itself to retail applications.
• Nestable 30” x 42” “Half” Pallet is an ideal pallet for retail and direct store delivery applications. It is specifically designed to fit through a standard doorway, and pallet’s lightweight design and ergonomic handles improve handling safety and efficiency.

All of the pallets mentioned above are 100% recyclable and available in recycled material.

If you’re looking for plastic pallets for distribution, Monoflo has what you’re looking for. Our wide variety of pallets are designed to suit your application requirements, and our industry experts can help you identify the most effective solution to address your performance needs. For more information or to check out our plastic pallet products, get in touch with our team today.

Plastic collapsible bulk containers are used for keeping goods safe and protected during transit and organized and clean when stored. They can accommodate large quantities of product and can be collapsed when not in use, saving storage space and shipping costs.

Benefits of Plastic Bulk Containers

Plastic bulk containers offer many benefits to their users:

Reusable & Repairable

Plastic bulk containers are reusable and have a long lifespan making them extremely cost-effective. They are also easily repairable, so if a piece does break, the container can be repaired quickly in the field and put back into use without causing disruption to productivity.

Plastic Bulk Containers are Recyclable

Once a plastic bulk container reaches the end of its useful life, it can be easily recycled, and the material can be used to make new products. Plastic bulk containers can also be manufactured using recycled material. And since the plastic they’re manufactured with is reusable, it eliminates the waste of single-use packaging, contributing to a more sustainable packaging system.

Reduced Freight Costs

A significant benefit of a collapsible bulk container is reduced freight costs. They can be efficiently folded when empty and are lightweight compared to other containers on the market. This delivers back-haul efficiency, reduces your carbon footprint, and conserves valuable warehouse space when not in use.

Strength & Durability

Plastic bulk containers are incredibly durable and strong. Designed to withstand the rigors of a challenging supply chain, plastic bulk containers reliably protect the items they contain, offering superior product protection.

Why Choose High-Pressure Injection Molded Plastic Bulk Containers?

Different materials and molding processes are used to manufacture plastic bulk containers.

High-pressure injection molded bulk containers are among the top-performing containers in the industry.

Better Strength-to-Weight Ratios

Injection Molded Bulk Containers offer the best strength-to-weight ratios, demonstrated through in-depth comparative tests. High-pressure injection molded bulk containers continue to outperform products made through other processes. Their light weight also makes them more user-friendly than other bulk bins, as an individual person can erect or collapse the container quickly and without issue.

Significantly Less Breakage Than Structural Foam Containers

High-pressure injection molded bulk containers are more durable than other plastic containers on the market. They experience significantly less breakage than containers made of structural foam, another commonly used material in bulk container manufacturing.

Structural foam products contain large air pockets, creating brittle areas that diminish the structural integrity of the product. In contrast, high-pressure injection molded products are 100% plastic and contain no air pockets. This eliminates the risk of weak or brittle areas, providing better protection to the contents within the bulk box and delivering a longer product life.

Easily Repairable

Plastic bulk containers are also designed to be easily repairable in the field. For example, imagine a bin’s sidewall is damaged after impact by a careless forklift driver. That sidewall can be swapped out in a matter of minutes. The bulk container is quickly returned to service rather than decommissioning the entire bin for isolated damage.

Why Monoflo for Bulk Collapsible Containers

A Leader in the Industry

Monoflo was one of the first manufacturers in the United States to make a bulk container using high-pressure injection molding, and we have over one million bulk containers made and in service today. Our bulk containers set the industry standard, delivering the highest strength-to-weight ratios in the industry.

Consistency & Quality

Cutting-edge automation and high-speed robotics are an integral part of our manufacturing, allowing us to maintain the highest possible repeatable quality and consistency. Technology helps deliver quality products and enables us to guarantee reliable repeatability so the first product in the run is exactly the same as the last.

Low-Cost

Monoflo continues to make significant investment in technology. Our manufacturing cells combine the most advanced high-speed robotics, energy efficient molding machines, and high-end tooling to enable us to decrease cycle times while maintaining the highest quality standards. The result is a perfect bulk container at the lowest cost.

Simply put, Monoflo bulk containers are designed to perform, and they deliver on that promise.

Monoflo’s product experts have decades of experience and can help you find the right solution to meet your performance needs. We have a wide variety of sizes and customization options, including tracking technology like RFID and Bluetooth. Get in touch with our team today for more information or to check out our bulk container product offerings.

How Monoflo International redesigned the Bulk Container to offer a better product with significant cost savings to the automotive and manufacturing industry.

Challenge: Design a more durable Bulk Container and drive down costs.

Monoflo International, Inc. is a premier manufacturer of superior quality injection molded plastic products and one of the first transport packaging manufacturer in the United States to make a bulk container using high-pressure injection molding. Monoflo believed that the high-pressure injection molded product line offered its customers better strength, durability, and price. Though it was outperforming the competition, Monoflo knew its first generation “G1” bulk box had room for improvement in three main areas:

» Packout Efficiency

Companies in the durable goods manufacturing industry work with a variety of vendors and suppliers, so members in that supply chain follow recommendations and best practices set by the AIAG (Automotive Industry Action Group) to standardize processes and materials, like bulk container footprints. The AIAG determined that the optimum bulk container size to accommodate the needs of the automotive industry is a 48”x45”footprint. However, when loaded on a 53’ trailer, the standard bulk container footprint could leave over 290 cubic feet of unutilized space.

» Durability

The supply chain can be unforgiving. Regardless of the manufacturer, customers across the industry experienced breakage of the container’s wall hinges as a result of wear and tear and abuse. Broken containers are costly to continually replace, but if left in use, can leave the product they carry vulnerable to damages.

» Manufacturing Efficiency

Resources are finite. Increased inputs of time, energy, labor, and raw materials can collectively drive up production costs. In order to keep costs low and promote sustainability, Monoflo wanted to drive out manufacturing inefficiencies.

Solution: Monoflo’s redesigned “G2” bulk box.

Monoflo set out to reengineer its bulk box design and manufacturing process to better use the real estate in a 53’ trailer packout, improve the durability of the bulk box to withstand the rigors of the supply chain, and increase manufacturing efficiency to reduce costs.

Monoflo understood it was important that the new design maintain the same inside dimensions to be able to accommodate the same dunnage and products without disruption to current users, and needed to be fully compatible with the other containers used in the durable goods manufacturing industry. Through careful calculation and modeling, Monoflo engineers identified a way to move from a 48” x 45” external footprint to a 48” x 44.5” external footprint without impacting the dimensions inside the container or the container’s strength. The team strategically positioned the feet of the second-generation base to ensure the new model would stack with the legacy models. These changes enabled customers to fit two additional container stacks in a 53’ trailer packout.

The redesign also included modifications to improve the strength and durability of the bulk box, and offered a solution to the industry-wide hinge breakage problem. Monoflo engineers created a redesigned “Flex Hinge” without fiberglass or metal for easier assembly and disassembly, and repositioned them towards the center of the sidewall to protect from wear and tear and abuse. This also made the unit more easily repairable, providing customers the option to repair instead of replace damaged containers. The team also established an independent “T-Slot” connection between the bottom and the sidewall, offering a more precise alignment when assembled, and a box-style “Carcass Joint” to better absorb and resist impact. Lastly, using Finite Element Analysis (FEA), Monoflo implemented a “U-Channel” ribbing design down the sidewall load lines to improve both vertical and horizontal deflections and optimize stacking capacity.

Monoflo performed a comprehensive evaluation of the machines it was using to manufacture bulk containers. Deciding it was time for an upgrade, the company made a significant, multi-million dollar investment and hand selected only the best-in-class robotics and machinery to fully automate the manufacturing process of the newly designed “G2” bulk container.

Results:

» Decreasing the external footprint of the container by 1⁄2 inch meant that 252 units could now ship in a single truck, an increase of 20% from the previous capacity of 234 units. For businesses that move thousands of truckloads of product across the country each year, this translated into significant cost savings. Customers not only pay a lower per-unit price on their initial order, but are also able to transport more product with each truckload.

» The improved“G2”Bulk Container with the new “Flex Hinge,” “T-Slot,” and“Carcass Joint” features has the highest strength-to-weight ratio in the industry as well as decreased reports of broken hinges. The “U-channel” ribbing offers improved load distribution, translating into the highest overall load stacking capacity and increased wall rigidity, both when assembled and disassembled. These strategic design optimizations enabled Monoflo to create a stronger, more durable container with improved load distribution while reducing the overall product weight by 20%, meaning less raw materials consumed and lower freight costs throughout the life of the product.

» Monoflo’s technology investment completely automated the bulk box manufacturing process, decreasing cycle times by nearly 6% and creating a manufacturing cell cost savings that Monoflo was able to pass on to customers. The upgraded technology also includes a vision verification system to inspect minute details at critical stages of production, eliminating the risk of misassembled product and guaranteeing consistent, repeatable quality.

Every factor of the redesign, from the increased packout count, to the improved durability and repairability, and the ongoing freight cost savings contributes to a lower total cost of ownership to customers. The new G2 Bulk Container offers a better quality, more durable container for a lower upfront price and freight savings for the life of the product.