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5 Reasons to switch to plastic crates

Secondary packaging containers such as plastic crates Melbourne, totes, bins, trays, baskets, etc. are common in Melbourne, but are just catching on in Australia. While cardboard has always been a popular choice in Australian warehouses, it can easily be damaged during the order picking and shipping process. Plastic crates are a great option. They are easy to store. And, they can prevent handling problems and ensure that customers receive undamaged, quality goods.

Here are five reasons to switch to plastic crates:

1. The box can handle heavy products

While cardboard can handle the lighter end of the spectrum, plastic is stronger to handle heavier loads. Plastic crates Sydney is also more durable, meaning they will withstand impact, vibration and pressure as they are moved in and out of storage, picked up, packaged and shipped.

2. Easy storage and retrieval

In an automated storage and retrieval system (AS/RS), containers are often densely stacked for storage on the warehouse floor. Cardboard boxes can vary in size and shape, so it’s easy to end up with an unbalanced load or unexpected spillage. On the other hand, plastic crates are available in standardized sizes that allow for safe, secure stacking.

3. Health and Safety

Dust, dirt and spills are easy to clean from plastic containers. They can also be sanitized, which is especially beneficial when adhering to strict health and safety standards.

4. Environmental factors

Is your warehouse hot and humid? Or is it a cold storage facility? While cardboard containers can easily warp or degrade, plastic better withstands moisture and extreme conditions without losing structural integrity.

5. Sustainability Goals

While cardboard boxes are relatively cheap, they don’t last long. Plastic crates can be reused – sometimes hundreds or even thousands of times – which reduces waste. This can save you big in the long run and tie in perfectly with your facility’s green initiatives.

Choosing an option that best suits your system of choice

The best storage packaging option will ultimately depend on the type of order picking system you are implementing. For example, in a case picking system, plastic crates are your best option due to their uniform size, strength and stability. And in cargo-to-person setups, plastic totes are most compatible with AS/RS and high-speed conveyor systems.

With an automated layer pick system, however, you’ll find that cardboard cartons offer the most organized way to create perfect layers and rainbow palettes.An automation system provider can help you make your decision and guide you through the right solutions for your business. And if you already use specific containers, an experienced provider can design your system with equipment optimized to accommodate your existing packaging.

Manufacture of plastic crates

Plastic crates are mostly made of high-density polyethylene (HDPE) or polypropylene (PP). Polyethylene has high impact strength and little degradation by ultraviolet radiation, while polypropylene has better scratch resistance. To improve the performance of both materials, antioxidants and UV protectors can be added.

The type of plastic manufacturing process depends on the form of the plastic crate. Each type of plastic crate has its own unique shape and design that makes one type of manufacturing process better than others. Below are some common ways to make plastic crates.

Injection moulding process

Injection moulding is a plastic manufacturing process in which molten plastic raw material is injected into a closed chamber or mould. There are three main steps in this process:

  • Grinding and heating the plastic until it flows under pressure.
  • Insert the plastic into the mould and allow it to cool.
  • By opening the mould to eject the plastic container.

Reciprocating screw type extruders are mainly used in industry to produce plastics for compounding; Screw type extruders require frequent mixing and kneading. When the plastic (raw material) is ready to be injected, the screw moves, pushing the plastic out of the extruder and into the mould.