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A kitting line feeds four assembly stations from one supermarket aisle. When the tote for a brake caliper family was still cardboard, the aisle ran out of usable bins by mid-shift: damp pallets, crushed corners, and a foam insert that had to be cut fresh for every damaged box. The line switched to molded EPP boxes, and the aisle stopped being the bottleneck.
One tool, box and cushion together. Because the box is molded as a single EPP part, the cavity that positions the casting and the walls that take the stacking load are the same piece. There is no liner to lose in the wash and no glue joint to fail after a winter. Bead fusion is uniform, so corners that used to dent in the milk run now spring back.
Weight the tugger notices. EPP at 60 grams per liter cuts the tare enough that a fully loaded train stays within the tow tractor rating, which matters when the route adds two stops. Workers lift empty boxes one-handed, and the molded hand grips sit where gloves actually reach.
Spec list:
EB 4315: 430 x 315 x 150 mm outer, 60 g/L EPP, payload 12 kg, 1.1 kg tare.
EB 4330: 430 x 315 x 300 mm outer, 60 g/L EPP, payload 20 kg, four high loaded.
EB 5435: 545 x 435 x 350 mm outer, 70 g/L EPP, payload 30 kg, six per Euro pallet layer.
Nesting: 62% empty-box height reduction, no tools to collapse.
Cleanability: open-rack wash at 60 degrees C, dry cycle 20 minutes.
Taking a family of parts into EPP. Send the part drawing and the station layout. TOYOE returns a cavity proposal with load points, a stack test report on the actual box, and tooling cost split across the planned annual volume. First articles follow the sample sign-off, and the tool is archived so repeat orders never drift.
Ask for a route trial: three boxes, two weeks, one real milk run.
