Think custom-design means expensive? Allow me to change your mind. In this post, I'll show you how expert crate design and a return program can add up to big savings.

I'll even back it up with a real-life example of a returnable crate design that resulted in immediate payback for one manufacturer.

Reducing Waste Saves Money

A crate made to fit your specific product reduces waste. Think about that. Using the exact amount of the right materials means you won't be paying for stuff you don't need.

Packaging engineers take into consideration every detail of your product including size, weight and handling requirements. The result is a durable and custom wooden crate optimized to use the least amount of resources. Less waste can make for a big reduction in your build cost and transport fees.
  

The More you Reuse, the More you Save

Plain and simple, reusability is often the biggest factor in reducing costs. The more times you can return a crate, the more opportunities you have to increase your savings. 

Return costs are based on pick-up locations and volume. Last year The Nelson Company managed return programs from over 2,500 pickup locations. Want to know if your operation is a good candidate for returning and reusing wooden crates? Check out my reverse distribution blog post, Packaging Return Program: Is it for me? 
​  

Payback can be Quick

This is where custom design gets interesting - especially if you've been dealing with shipping damage. Let's look at that example I promised. A toilet manufacturer now uses custom clips crates for shipping their prototype toilets to laboratories across the globe. The toilets need to be tested at multiple labs and then brought back for further analysis. Reusable clip crates were a natural fit.

The customer's old way of shipping was causing damage rates as high as 25%. The new design reduced damage to 0% and paid for itself in about one trip. The clip crate design is easy for workers to pack up plus the company only needs 10 of these perfectly-optimized shipping crates to get the job done. As expected, each shipment of prototype potties in custom crates improves savings.

Ready to save big?

If you've been avoiding custom design because you feared it would cost too much, I hope this post showed you it doesn't have to be that way. If you've been tasked with reducing your damage rates or shipping costs, ask a question below or drop me a line and let's get to work on saving money.

Post by: Kent Longardner, Technical Sales Manager

If you're shopping for plastic pallet containers, you may be wondering if you really need a lid. I get asked that question all the time. Especially if we're talking about stacking the containers. 

The answer is (as you probably guessed) that it depends.

Stack with or without a Lid
Plastic pallet containers are designed to stack safely. The bottom is inset to nest about a half inch into the container below it. This nesting feature allows you to move stacked containers without concern of a container slipping off the stack. Pallet containers can stack with or without lids.

Reasons for a Lid
If your product needs to stay protected from damage or environmental elements like dust, a lid is in order. You may also want to use lids to prevent theft when shipping pallet containers. Many customers band the lid and container together. Others add modifications including hinges and padlocks for beefing up their loss prevention efforts. Lids also make the container resistant to weather damage. While not all containers are waterproof, your contents should be safe during transit if moved in inclement weather.

Choose a lid if you need:

• product protection
• security

Reasons for No Lid
Some plastic bulk containers are designed with a drop gate for easy access to contents. Unfortunately, when you put a lid on your container, you can no longer open the drop gate. The lid waterfalls over the outside edge of the container by about two inches. If the container will be in transit, however, the waterfall (or overhang) is an advantage because it provides security. You don’t have to worry about someone accessing your contents while the container is moving.

Further, agricultural users concerned about moisture and mold will benefit from using pallet containers with vented walls and no lid. A vented container allows moisture to escape, reducing environmental conditions conducive to mold and decay. This helps to keep the produce fresher longer. I explain this in more detail in my previous post about using plastic containers for NC sweet potatoes.

Skip the lid if you need:

• easy access to contents
• better air flow

Customizing Lids
Companies that use a lot of pallet containers have the option to emboss lids with their name or company logo. This helps to claim ownership and prevent loss of the lid itself. To qualify, you must be a heavy container user. The minimum order for containers with customized lids is two truckloads (about 200-500 containers depending on size).

Do you use plastic pallet containers with or without lids? Tells us below or ask me if a lid is right for your application.

Post by: Penny Peirce, Sales Representative

www.nelsoncompany.com/containers.cfm?Group=CollapsibleAre empty containers taking up too much room in your warehouse?

When not in use, collapsible plastic containers fold to a fraction of their size and can drastically increase your available warehouse space.

How do they Work?

Easy. Look for the different colored handles.

• Lower and Raise the Drop Gate
  When you pull the inside two yellow handles toward each other, a drop gate folds down. This drop gate articulates to the outside of the container. To close a drop gate, simply lift it up and snap it back into place.
    
• Collapse the Container
  The gray handles located on two opposing sides of the container do the job here. Starting on one side, simply pull the two gray handles towards each other and the wall will collapse in. Do the same on the opposite side. The two remaining walls can then be folded inwards. That's it!
    
• Unfold and Use Again
  To unfold the box, reach in and pull up the first side wall. It will snap in place. Do the same with the opposite wall. Then, reach in and pull the next one into place and finally the fourth wall. Voila! Your container is ready to handle 2000 lbs.​

Collapses to About a Foot

A standard 48x45x34" plastic container like the ones shown here will collapse down to less than 13". As you can see, collapsible plastic containers are a snap to use and store.


What will you do with all that extra space? Tell me in the comments below.

Post by: Penny Peirce, Sales Representative

Ventilated plastic bins play an important part in North Carolina's sweet potato industry. 

So the next time you order up some sweet potato fries with a dusting of cinnamon you can thank the smooth and moisture-resistant qualities of ventilated plastic containers for keeping those taters fresh. That's because the way these spuds are planted, harvested and stored can all have a significant impact on the quality of the sweet potato. 

From Seedling to Harvest to Curing

According to USDA figures and the North Carolina Sweet Potato Commission, 400 farmers planted 60,000 acres of sweet potato in 2010 worth about 182 million dollars to North Carolina's economy. That's roughly half of the US supply. How exactly do plastic bins help? 

Well, sweet potatoes are grown from "slips". These are live seedlings and must be kept in containers that will not collect any moisture. Ventilated bins are required for this step. Later, when the potatoes are harvested, they again need to be kept in ventilated bins.

Now, this part may surprise you. Most producers cure the sweet potato to be "sweet" over the course of several weeks. That's right, these tasty tubers are not naturally sweet. Who knew? They are kept in a climate controlled environment where the potatoes need to be exposed to exacting levels of humidity and heat. And, you guessed it, ventilated bins are used for the curing too. 
 
  
Plastic vs Wood Agricultural Bins

A plastic ventilated bulk bin for agriculture offers many improvements over wood:

• Moisture Resistance
  First and most importantly, plastic bins do not hold moisture. Wood not only absorbs moisture but chemicals too. Wood bins "weather", resulting in rough surfaces which can harbor various disease-causing organisms. Plastic bins are smooth and can be sterilized.
  
  
• Better Ventilation
  The ventilation slots in a plastic bin amount to 7–11% of the surface area compared to plywood bins at only 1.5%. With better ventilation, you can stack your produce closer together and still have sufficient air movement through the stacks. Plus, an interlocking system provides safer and possibly higher stacking.
  
  
• Safer Handling
  Plastic has no nails or splinters to puncture food or injure handlers. The bin floor and walls are smooth. At 30-40 lbs each, plastic ventilated bins are lighter and easier to lift than wooden agricultural bins.

Long Lifespan

With proper handling, you can expect plastic sweet potato bins to last about 15 years. And, when they've reached the end of their useful lifespan, they can be recycled. Always consistent in size, plastic ventilated bins will not warp, splinter, or weather making them a great choice for sweet potatoes and the agricultural industry.

Do you use plastic bins in agriculture or have questions? Please let me know in the comments below.

Post by: Penny Peirce, Sales Representative

Determining the optimal crate design can be difficult. Multiple materials, different designs and countless closure methods create unlimited choices for wooden crates.

Crate designers must focus on four basic package functions to drive their decisions.  
These four functions are:

1. Containment
   This is the most basic of the package functions. Containment means the crate should contain the product. A lawnmower could use an open frame crate, but a crate of bearings may need to be sheathed and have solid walls for extra containment
     
2. Protection
   How much packaging is too much? Once the product is contained, then it must be protected. The three general environments that the product needs protection from are: physical, ambient, and human. Each environment creates different challenges for the design of the crate.
     
3. Convenience (Utility)
   The convenience of the crate is paramount for shipping, customer experience (ergonomics), and the overall ease of use. Taking into account how the crate will be handled, opened, and unpacked are all important factors that must be taken into account when designing the crate.
    
4. Labeling/Branding
   What visible information is needed on the crate exterior throughout the distribution environment? Some significant information includes UPC, proper handling instructions, assembly instructions, shipping details, international markings, safety and more.
   
   

Is your crate meeting all the requirements needed to contain, protect, and distribute your products? Tell us about your successes and challenges in the comments below.

Post by: Kent Longardner, Technical Sales Manager

We love wood crates. There are many benefits for using wood crates. Here are my top reasons to choose wooden crates for your next shipment. 

Wood crates:

• Offer enhanced protection
  Wood crates can reduce product damage. The crate will act as a barrier from the environment, protecting what’s inside from moisture, dirt and other debris floating around the exterior environment.
    
• Are great for stacking
  Crates allow you to utilize more space in shipping and in your facilities. Placing one crate on top of another allows you to stack them, utilizing the height of your facility and saving precious floor space.

Which wood crate benefit is your favorite? Let us know why by commenting below.

Post by: Kent Longardner, Technical Sales Manager 

Plywood and OSB (Oriented Strand Board) panels are the most common sheathing materials used for wooden crates. If you need a sheathed crate, which one is best for your application? 

Here are the options:

• Plywood
  layers (usually 3 to 5) of thin wood veneers glued together to form a thicker panel.
    
  
• OSB
  layers of large chips, glued together to form a thicker panel.

For BOTH plywood and OSB, layers are rotated 90 degrees so that the overall panels have strength, stiffness and stability in all directions. Most of the panels used in pallets and crating are industrial grade and similar to that used in the housing industry. 

Within the housing industry, plywood and OSB are considered interchangeable. The load ratings are usually based on the panel thickness, rather than materials. 

For pallets and crating, plywood and OSB are NOT interchangeable. 

Here are some of the factors to consider:

• Durability 
  For outdoor applications under damp conditions, plywood is more durable than OSB.   Standard OSB panels will degrade over time, so plywood wins for outdoor use.
• Strength and Stiffness
  There is no difference in this category. 
• Appearance
  Plywood wins for most applications. The finished plywood unit has a smooth appearance and is more aesthetically appealing to most users.
• Weight
  Again, very little difference in this category.
• Cost
  Usually OSB wins here. Most of our OSB is used in the more cost sensitive applications, where performance and durability are required, but a lower price is a high priority. While the costs of plywood and OSB fluctuate, OSB is almost always the winner in the price factor.

So what do you think? Which material is best for your application? 

Post by: John Clarke, Technical Director

Use of OSB Panel by Lionel Allorge and Spruce Plywood by Bystander licensed under the Creative Commons Attribution 3.0 Unported license.

Remember when we told you that you could build custom crates fast? We showed you our reusable clip crates.

Well now we can show you how with this instructional video of a clip crate assembly.

  
Below is a  step-by-step summary of the clip crate assembly video. 

1. Start the assembly process by placing one crate side/end on top of the base and in its proper location.
     
2. Attach the first 2 clips, connecting the side/end to the base. Use a rubber mallet to assist in attaching the first two clips.
     
3. Place the next side/end panel against the base and first-installed panel.
     
4. Install additional clips connecting this panel to the base. A firm push of the hand should suffice in attaching the clips. The clips will “snap” once they are properly in place.
     
5. Next, install clips along the vertical joint of the end and side panels.  
   
   
6. Make sure to install clips approximately every 12”.
     
7. Opposite panels will have internal cleats that will assist in positioning the panels. 
     
8. To finish fastening the sides/ends, attach the necessary clips to the horizontal and vertical joints.
     
9. Once all of the sides and ends are in place and properly clipped, put the top panel in place.
     
10. Install the clips to the top panel and each side and end. These connections will be tight and may require the use of a rubber mallet.
      
11. During the entire process, make sure to use the appropriate safety equipment (PPE).
      
12. To remove the clips, simply insert a flat head screw driver underneath the clip, cover the clip with your hand, and pry away from the crate.

Do you have a need for a quick assembled clip crate? Let us know by commenting below.

Post by: Rich Reiher, Vice President

Gaylord was originally a trade name for a bulk-size corrugated box.

You have probably seen a Gaylord box in your local grocery or big box store. They are big corrugated boxes attached to wood pallets. These corrugated containers usually hold a bagged product or fresh produce like watermelons.

Sometimes a trademark becomes a commonly-used term. For example, Kleenex® has become synonymous with tissue. And, most people now refer to an adhesive bandage as a Band-Aid®. In the materials handling business, the same is true for Gaylord.

Once only used for identifying jumbo-sized corrugated boxes, Gaylord has evolved into a generic term for any pallet-sized box for bulk shipping or storage. These hefty containers are also referred to as:

• Pallet Containers
• Bulk Boxes
• Pallet Boxes
• Bulk Bins
• Skid Boxes
• Tote Boxes

Gaylord boxes manufactured from corrugated are intended for low volume and have a relatively short lifespan. This makes them popular for agricultural use. The use of corrugated makes them inexpensive and easy to replace.

Gaylord boxes are available in single, double or triple-wall construction in both corrugated paper or plastic. The corrugated plastic is intended for long-term use, however, corrugated material will not withstand heavy handling.
 
In heavy handling applications, bulk boxes made from recycled plastics can withstand rugged industrial use, like the collapsible container. Under non-abusive conditions, plastic Gaylord containers will last many years.

For applications requiring FDA-approved containers for direct food contact, virgin plastic materials allow the agricultural industry to choose plastic for Gaylord requirements.

Do you know Gaylord boxes by another name? Tell us below in the comments.

Post by: Penny Peirce, Sales Representative

There's an easier way to build custom crates - without tools. Plus you can save money!

Would your company like to crate products but there's simply not enough space in your shipping area? If your space is not the issue, is nailing or screwing crates together creating hassles and slowing down your workers?

Save both time and space with the Nelson Clip Crate. 

1. No Tools: all that is required to assemble these crates are metal clips and a small amount of hand-applied pressure.
     
2. Fast and Easy: the Nelson Clip Crate utilizes specially manufactured crate components that can easily be assembled on site by anyone.
     
3. Everything is Included: Nelson Clip Crates are packaged into kits that come with all the necessary elements for assembly. 

The Nelson Clip Crate can be made in your choice of materials including:

• Lumber
• Plywood
• OSB (Oriented Strand Board)
• MDF (Medium Density Fiber Board)

Clip Crates customized to your size and shipping requirements.

Shipping: The Nelson Clip Crate can be designed to be reusable or for one-way  shipments. Clip crates disassemble easily for reuse. Exporting? We can produce the crates in compliance with ISPM-15 standards for international trade.

Standard and Custom Sizes: The crates can be adjusted to fit almost any size requirement. Current Nelson Clip Crates range in size from 2 feet to over 10 feet in length.

Interior Options: Custom interior dunnage including shelves, trays and gussets can be designed to fit inside the Nelson Clip Crates. Custom options are included in the kits shipped to you.

Does the Nelson Clip Crate sound like your perfect solution?

Do you want to build custom crates in less space and faster than traditional crating solutions?

Would you like to hear about a money-saving Nelson Clip Crate case study?

Get in touch with the Nelson Company today!

Post by: Rich Reiher, Vice President of Sales