Reusable Packaging: Benefits, Challenges, and Examples

Environmental responsibility is a hot topic these days, and companies across many industries are making strides to reduce their impact in a variety of ways. With packaging producing massive amounts of waste each year, many are looking to adopt reusable packaging solutions. 

But what is reusable packaging and how can you use it in the real world? Let’s look at what we mean by reusable packaging, the benefits of reusable packaging and common challenges.

What is Reusable Packaging?

Reusable packaging is exactly what it sounds like: packaging that’s designed to be used more than once. This differs from traditional packaging, which is typically thrown away or recycled after a single use. 

Ideally, reusable packaging can be used multiple times and eventually should be recyclable. Reusable packaging can refer to a complete packaging solution, such as a plastic container or crate, or any part of a packaging system that has a multi-use lifecycle.

Types of Reusable Packaging

Common applications include reusable industrial packaging, reusable transport packaging, reusable containers and reusable plastics. In the packaging industry, there are two primary types of reusable packaging: refillable and returnable.

Refillable Packaging

Refillable packaging is designed to be used again and again for the same type of product. Examples include refillable glass bottles, plastic or wooden crates and reusable containers such as cardboard shipping boxes. This type of packaging can be refilled by the customer, the manufacturer or whoever receives it next.

Returnable Packaging

Returnable packaging is designed to be sent back to the manufacturer and used again. Manufacturers can collect the packaging directly from the customer or the customer can return it to a designated drop-off location. Reusable transport packaging such as crates, boxes and pallets are common examples of returnable packaging. In some cases, reusable plastics may also be returnable.

Commonly Used Reusable Packaging Materials

Reusable packaging requires sturdy, durable materials that can be easily cleaned between uses. For healthcare or medical applications, it must be sanitized. Common materials used include reusable plastic, glass, metal and compostable materials such as mushroom fiber and bioplastics.

Benefits of Reusable Packaging

The environmental and economic benefits of reusable packaging include:

• Reduced Waste
• Resource Conservation
• Cost Savings
• Brand Boosting
• Supply Chain Efficiency

Reduced Waste

Packaging produces millions of tons of waste each year, adding to environmental degradation and pollution. Adopting reusable industrial packaging alongside commercial options helps to reduce the amount of single-use packaging materials that end up in landfills, minimizing environmental impact.

Resource Conversation

Reusable packaging also reduces the volume of raw materials that are consumed in the packaging industry each year as well as the amount of energy needed to turn those raw materials into finished packaging. Conserving natural resources reduces the overall carbon footprint and increases sustainability.

Cost Savings

Although reusable packaging solutions may have a higher price point than single-use options, getting multiple uses out of them can lower your packaging costs over time. The more times a package or system can be reused, the more you save.

Brand Boosting

The growing consumer trend towards eco-friendly purchasing includes choosing companies that use environmentally friendly packaging. Clearly labeling your packaging solution as reusable can help you win over green shoppers and boost your brand reputation.

Supply Chain Efficiency

Replacing single-use packaging with reusable containers helps to optimize logistics and minimize supply chain needs such as transportation, material handling and waste disposal, increasing the overall efficiency of your operation. 

Challenges of Reusable Packaging

Despite these business benefits, reusable packaging also involves some challenges. If you’re looking to implement reusable packaging systems, keep these things in mind.

• Compliance Issues
• Sustainability
• Hygiene
• Costs
• Risk of Loss

Compliance

Reusable packaging requires consumers to return it. Otherwise, it ends up being single-use at an even higher price point. If your customers are reluctant to do the extra work, a reusable packaging scheme will fail. Be sure to get customer buy-in before you invest.

Sustainability

While effective reusable packaging programs can reduce environmental impact, it’s important to calculate how many uses you need to get out of a container for it to reach that tipping point. The need to recover and clean containers in between uses can drive up energy consumption, increasing your carbon footprint. If only a small number of uses are likely, it might be better to opt for another eco-friendly or recyclable option.

Costs

To make packaging reusable, it must be durable and cleanable. That requires sturdy materials that may cost more than traditional single-use counterparts. For example, reusable plastic tends to have a higher price point than single-use plastics. It’s important to calculate these costs and make sure you will be able to get enough uses out of reusable packaging solutions to be cost effective.

Hygiene

Cleaning reusable containers in between uses is critical, especially for healthcare/medical and food products. But this requires natural resources and energy, which can impact both costs and sustainability. It’s also an additional step in your supply chain.

Risk of Loss

Reusable packaging solutions are necessarily higher quality than single-use containers, which makes them more susceptible to theft. Deposit schemes, like those used by many states and municipalities to incentivize recycling, can help. But loss prevention is a barrier to efficiency that should be considered up front.

Reusable Packaging Examples

In the food and beverage industry, refillable milk bottles were the original reusable packaging solution. Today, refillable beverage kegs are a more common example along with reusable crates and pallets for transporting produce and other fresh food products. Glass jars are also widely used, and some restaurants are starting to replace single-use Styrofoam and plastic containers with reusable options for takeaway.

In the retail industry, reusable shopping bags are popular with consumers. Stores that offer beauty and personal care products in bulk are also becoming more popular, with refillable packaging available for multiple uses. In some cases, these stores are part of the zero-waste packaging movement that looks to take going green even further.

Industrial packaging calls for optimal strength and durability, often being used to transport heavy goods through longer supply chains. Examples of reusable industrial packaging include pallets, bins and tanks, trays and dunnage, and durable reusable plastic containers. Returnable packaging systems such as modular and stackable solutions are also a smart option for industrial needs, and may be customizable to meet precise requirements.

How Ernest Can Help with Your Reusable Packaging Needs

If you’re interested in boosting your brand and reducing your carbon footprint with reusable packaging solutions, Ernest can help. We can assess your products and processes to find the best multi-use option. And if the costs and challenges are too high for your business, we can recommend another eco-friendly option. Sustainability is in our DNA and our design experts can customize a packaging solution for your unique needs. We love a challenge almost as much as we love delivering results. Let’s talk.