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Every kilogram in a returnable container pays freight twice: once outbound with parts, once inbound empty. A solid plastic box with a separate foam liner carries a lot of dead weight, and every assembly step adds a part that can be lost on the line. Our EPP containers mould the walls, the liner and the cushioning into a single part, which cuts both the weighbridge ticket and the housekeeping.
One mould, one part
Steam-moulded from fused beads, the container comes out of the tool finished: box walls, integral lid seating and a liner cavity shaped for the part family. There is no liner to insert, no clips to lose, and no seam where two components wear against each other. Fewer SKUs in the wash bay and a shorter bill of materials for the packaging engineer.
Light, but not soft
Bead density is tuned by zone: 45 kg/m3 in load-bearing walls, 60 kg/m3 under the liner floor, 30 kg/m3 in lid ribs. A full-size container set lands at roughly a third of the weight of an equivalent rotomoulded box plus liner, while still carrying 150 kg of parts and stacking three-high in the trailer.
Standard container platforms
LW 1210: 1200 x 1000 x 800 mm outer, integral liner cavity, payload 150 kg, three-high stack.
LW 865: 860 x 650 x 560 mm outer, payload 80 kg, nests when empty.
LW 604: 600 x 400 x 340 mm outer, payload 40 kg, hand-carry format with moulded grips.
LW-LID: matching moulded lids with bead-sealed edges for dust-sensitive parts.
Recycling that actually closes
Because the whole container is a single material, a damaged box does not become mixed waste. Retired containers are granulated and the beads re-enter production, and customers running closed loops can send end-of-life units back for credit. The material is inert, odour-free and passes UL 94 HB as standard.
Programme route
Bring us the part family, the stack height and the payload. We propose a bead density map and a wall section, cut prototype tooling for a field trial on your actual shuttle routes, and firm up production tooling once the trial miles are logged.
Send one heavy part and one fragile part from your range, and we will return a container concept with weights, stack ratings and tooling cost within three working days.
