Food transport packaging needs to do more than simply hold a product. It needs to protect food throughout the supply chain, cope with repeated handling and, in many cases, withstand moisture, temperature changes, stacking and demanding warehouse environments.
For many years, cardboard boxes have been a standard choice for transporting food. They are lightweight, readily available and convenient for one way distribution.
But for businesses moving food regularly, there is another option worth considering: reusable plastic crates.
Switching from cardboard to reusable plastic crates can provide a more durable and consistent approach to food transport, particularly for businesses handling regular deliveries and return journeys.
But is making the switch right for every food business? And what should you consider before replacing cardboard packaging with reusable plastic crates?
Why is cardboard still used for food transport?
Cardboard remains a popular packaging material across the food industry for several reasons.
It is relatively inexpensive to purchase, easy to source and lightweight to transport. For businesses that only need packaging for a single journey, cardboard can also be a practical option.
Cardboard boxes can be particularly useful when products are being sent directly to customers or retailers and there is no requirement for the packaging to return to the original supplier.
However, the same characteristics that make cardboard convenient for one way transport can become less attractive when businesses are moving large volumes of food repeatedly.
A business using hundreds or thousands of boxes every week needs to consider more than the initial cost of each box.
It also needs to consider replacement, waste, storage, handling, product protection and the practicalities of moving packaging through the supply chain.
What problems can cardboard cause during food transport?
Cardboard can work effectively in many food transport applications, but it has limitations.
Moisture is one of the most obvious considerations. Cardboard can lose strength when exposed to water, condensation or damp environments. This can be particularly relevant when transporting chilled or fresh products.
Repeated handling can also result in boxes becoming crushed, torn or damaged. Once the structural integrity of a cardboard box has been compromised, it may be less effective at protecting its contents or stacking securely.
There is also the issue of what happens after delivery.
A cardboard box generally has a relatively short useful life within a supply chain. Once it has reached its destination, it may be recycled or disposed of rather than returning to the sender for another journey.
For businesses transporting food on a continuous cycle, this can mean continually buying and disposing of packaging.
That is where reusable plastic crates can offer an alternative.
Why are plastic crates used for food transport?
Reusable plastic crates are designed to withstand repeated handling, transportation and storage.
Unlike disposable packaging, a reusable crate can remain within a supply chain and be used for multiple transport cycles.
Depending on the design, plastic crates can also offer several practical advantages for food businesses:
- Durable construction for repeated handling
- Resistance to moisture
- Easy cleaning
- Consistent dimensions
- Secure stacking
- Nesting when empty
- Protection during transportation
- Reduced reliance on single use packaging
- Better organisation within warehouses and distribution environments
The right crate will depend on the food being transported and the requirements of the supply chain.
For example, fresh produce may require ventilation, while other food products may benefit from a solid sided container. Businesses also need to consider load capacity, dimensions, cleaning requirements and how empty crates will be returned or stored.
Plastic crates vs cardboard boxes for food transport
The decision to move from cardboard to plastic should not simply be based on the price of one box compared with the price of one crate.
The more useful comparison is how each option performs across the entire transport cycle.
Durability
Cardboard is generally intended for single use or limited use. It can be damaged through moisture, impact and repeated handling.
Reusable plastic crates are designed to cope with repeated transport and handling. Their rigid construction can also provide greater consistency when crates are stacked, moved and stored.
Moisture resistance
Moisture can be a major consideration when transporting food.
Plastic crates are resistant to water and can be washed between uses, making them particularly useful in environments where spills, condensation or regular cleaning are part of the process.
Hygiene
Food transport packaging needs to be suitable for the products and processes involved.
One of the main advantages of suitable reusable plastic crates is that they can be cleaned and reused. This makes them an attractive option for supply chains where hygiene and repeatability are important.
Of course, simply choosing plastic does not automatically make packaging hygienic. Crates still need to be handled, cleaned and maintained appropriately for their intended application.
Reusability
This is perhaps the biggest difference between the two approaches.
Cardboard packaging will often leave the supply chain after one delivery.
Reusable plastic crates are designed to remain in circulation.
A crate can be delivered with a food product, returned, cleaned and then used again. Over time, this changes the way businesses need to think about their transport packaging.
Handling and stacking
Standardised plastic crates provide a consistent shape and size, making them easier to stack and organise.
This can help businesses make better use of warehouse and vehicle space while reducing the problems caused by damaged or misshapen packaging.
Cost
Cardboard can have a lower upfront cost, but that does not necessarily mean it is the cheapest option over the long term.
Businesses should consider the total cost of their packaging system, including:
- Packaging replacement
- Waste disposal
- Storage
- Handling
- Product damage
- Procurement
- Transport
- Return logistics
- Cleaning
- Expected lifespan
The right answer will depend on how frequently the packaging is used and how effectively reusable crates can be incorporated into the supply chain.
What are the benefits of reusable plastic food crates?
Reusable plastic crates can offer a range of advantages for businesses transporting food regularly.
Built for repeated use
A reusable crate is designed to go through multiple transport cycles rather than being discarded after one journey.
This can make them particularly suitable for businesses with established delivery and return routes.
Easier to clean
Plastic crates can be washed and cleaned between uses when the crate specification and cleaning process are suitable for the application.
This can be particularly useful for food manufacturers, processors and distributors where maintaining clean transport equipment is an important part of the operation.
Stackable for efficient transport
Consistent crate dimensions can make stacking more predictable.
Loaded crates can be stacked securely, helping businesses organise products within warehouses and vehicles.
Better stacking can also help businesses make more effective use of available space.
Nestable when empty
Some reusable crates are designed to nest inside one another when empty.
This can significantly reduce the amount of space required for storage or return transport.
For businesses sending empty packaging back through the supply chain, this can be an important consideration.
Consistent throughout the supply chain
A cardboard box can become crushed or damaged relatively quickly.
Reusable plastic crates maintain their shape through repeated handling, giving businesses a more consistent container for moving products from one stage of the supply chain to another.
Are plastic crates more hygienic than cardboard?
Plastic is not automatically more hygienic than cardboard.
The important consideration is whether the transport container is suitable for the food application and whether it can be properly cleaned and maintained.
Reusable plastic crates can provide advantages because they are generally easier to wash and clean than disposable cardboard packaging.
For businesses handling food, this can make reusable crates particularly attractive where transport containers need to be returned, cleaned and put back into service.
The material, crate design, cleaning process, storage conditions and handling procedures all need to be considered.
Which foods can be transported in plastic crates?
Plastic crates are used across a wide range of food transport applications.
Depending on the specification, they can be suitable for products including:
- Fresh fruit
- Vegetables
- Meat
- Prepared meals
- Frozen foods
- Bakery products
- Grocery products
- Food ingredients
- Processed foods
Different products will have different requirements.
Fresh fruit and vegetables, for example, may benefit from ventilated crates that allow air to circulate around the products.
Other applications may require solid sided containers that provide additional protection.
This means that choosing the right crate is just as important as choosing reusable plastic packaging in the first place.
What type of plastic crate is best for food transport?
There is no single plastic crate that is right for every food transport application.
The right choice will depend on factors such as the product, load, environment and logistics process.
Stackable food crates
Stackable crates can be placed securely on top of one another when loaded, helping businesses maximise available warehouse and vehicle space.
They can be particularly useful where products need to be moved and stored in standardised units.
Nestable food crates
Nestable crates are designed to fit inside one another when empty.
This can reduce the amount of space required for empty crates, making them useful where packaging needs to be returned to a warehouse or supplier.
Folding food crates
Folding crates provide another option for businesses that need to transport or store empty packaging efficiently.
The sides can be folded down when the crate is not being used, reducing the space it occupies during storage or return journeys.
Plastic pallet boxes
For larger quantities or heavier products, a plastic pallet box can provide a more substantial transport and storage solution.
These larger containers can be used for bulk handling applications where smaller crates would not provide enough capacity.
Ventilated plastic crates
Ventilated crates allow air to circulate around their contents and can be useful for fresh produce and other applications where airflow is important.
How do reusable plastic crates improve food logistics?
The benefits of reusable crates extend beyond simply replacing one type of box with another.
They can become part of a more structured logistics system.
Standardised crate sizes can help with warehouse organisation, stacking and handling. Nestable designs can reduce the space needed when empty, while durable construction means crates can move through the same supply chain repeatedly.
For businesses with regular delivery routes, this can create a more predictable packaging cycle.
Products leave the warehouse in reusable crates.
The crates arrive at their destination.
Empty crates return through the supply chain.
They are cleaned and prepared for their next use.
The cycle then starts again.
This is very different from a one way packaging model where new cardboard boxes need to be purchased for every shipment.
Can switching from cardboard to plastic crates reduce waste?
Reusable plastic crates can help businesses reduce their reliance on single use transport packaging because they are designed to remain in circulation for multiple uses.
However, it is important not to assume that reusable plastic is automatically the more sustainable choice in every situation.
The environmental impact of a reusable crate depends on how it is used.
Factors such as the number of reuse cycles, transport distances, cleaning requirements, crate lifespan and end of life recycling can all influence the overall picture.
Return logistics are also important.
A reusable crate that is transported long distances empty on every journey may have a different environmental profile from one that moves efficiently through an established delivery network.
The best approach is therefore to look at the entire packaging cycle rather than focusing on the material alone.
What is the true cost of cardboard food transport packaging?
The purchase price of a cardboard box is only one part of the cost.
If a business is using large quantities of cardboard every week, the real cost can include packaging procurement, storage, handling, disposal and replacement.
There can also be indirect costs.
For example, damaged packaging may contribute to damaged products. Inefficient stacking may affect how much can be transported in a vehicle. Time spent dealing with waste and packaging may also add to operational costs.
Reusable crates have their own costs.
Businesses need to consider the initial investment, cleaning, storage, return logistics and eventual replacement.
However, because a reusable crate can be used repeatedly, it makes sense to calculate the cost across its expected service life rather than comparing the purchase price of one crate with one cardboard box.
A simple cost per trip calculation can provide a much more useful comparison.
How can you move from cardboard to reusable plastic crates?
Switching packaging does not have to happen overnight.
A phased approach can help businesses establish whether reusable crates are suitable for their supply chain.
1. Identify where cardboard is currently being used
Start by looking at which products are transported in cardboard and how often those boxes are used.
2. Calculate packaging usage
Record how many boxes are purchased, how often they are replaced and how much packaging waste is generated.
3. Identify problem areas
Look for damaged boxes, moisture issues, inefficient stacking, storage problems or other packaging related issues.
4. Assess the products being transported
Consider the size, weight, fragility and characteristics of the food products involved.
5. Establish your crate requirements
Determine the dimensions, load capacity, ventilation, stacking and cleaning requirements.
6. Review your return logistics
A reusable crate needs to come back into the supply chain.
Consider how empty crates will be collected, transported and stored.
7. Compare total costs
Look beyond the purchase price and compare the expected cost per transport cycle.
8. Trial the system
Testing reusable crates on a particular product line or delivery route can provide useful information before introducing them across the entire operation.
9. Measure the results
Look at packaging costs, product protection, storage, handling, cleaning and return logistics.
This provides a clearer picture of whether reusable plastic crates are delivering the expected benefits.
What should you consider before replacing cardboard with plastic crates?
Before making the switch, consider:
Product requirements: What are you transporting and how much protection does it need?
Crate dimensions: Will the crate fit your products, shelving, pallets and vehicles?
Load capacity: Can it safely carry the required weight?
Ventilation: Does the product require airflow?
Hygiene: Can the crate be cleaned using your existing processes?
Stacking: How will loaded crates be stored and transported?
Nesting: How much space will empty crates require?
Warehouse equipment: Are the crates compatible with your existing handling systems?
Transport routes: How will empty crates return?
Storage: Where will empty and full crates be kept?
Cost: What is the expected cost per use across the crate’s lifespan?
End of life: What will happen to the crate when it eventually reaches the end of its useful life?
Looking at these factors before purchasing can help ensure that the chosen crate is appropriate for the entire logistics process, rather than simply replacing a cardboard box with a plastic one.
Why choose Exporta Global for food transport crates?
Choosing the right reusable crate is about more than finding a container that fits the product.
It needs to work within the wider supply chain.
Exporta Global supplies a range of reusable handling and storage solutions designed for businesses looking to improve the way they move, store and manage products.
The range includes different types of crates and containers for applications across food manufacturing, processing, distribution and logistics.
From reusable Bale Arm Crates and folding crates to larger plastic pallet boxes, the right solution will depend on the product being transported and how it moves through your business.
If you are considering moving away from cardboard, Exporta Global can help you assess the options available and identify a reusable transport packaging solution that fits your operation.
Ready to move beyond cardboard?
If your business regularly uses cardboard boxes to transport food, it could be worth looking at what reusable plastic crates could offer.
A more durable and reusable transport system can help businesses improve handling, organisation and repeatability while reducing their reliance on single use packaging.
The key is choosing the right crate for the application and considering the entire supply chain, from loading and transport through to cleaning, return and reuse.
Looking for the right food transport crates for your business?
Explore Exporta Global’s range of reusable crates and containers or speak to the team about your requirements.
