Volume-reducible transport containers: save space on empty runs

Return transports of empties cost money – often more than companies realize. Those who return built-up, non-foldable containers waste loading space capacity and pay for journeys that are half empty. Volume-reducible transport containers solve this problem: they can be folded to a fraction of their original volume after unloading – and thus structurally reduce return transport costs.

With the ThorPak product family, wi-sales GmbH offers foldable KLTs (R-FSC, RL-FSC), foldable large load carriers (Quattro) and individual system solutions for automotive, industry and logistics. This page shows when the changeover pays off – with concrete figures.

The problem: High costs due to transportation of empties

A disposable container solves the packaging problem at one end of the supply chain – and creates a new one at the other. Anyone who transports goods in non-foldable KLTs or large load carriers (GLTs) regularly sends half-empty trucks on return trips.

A 13.6 m long trailer can hold around 180 units stacked with 600×400×280 mm Euro containers when assembled. Depending on the type, the same containers occupy less than half the stacking height when folded (example R-FSC 6429F: 280 mm when set up → 90.5 mm when folded). This means that up to three times as many empty containers can be transported in the same loading area – return trips are reduced accordingly.

Added to this is the need for storage space: empties are waiting to be collected. In many factories, built-up empty containers take up valuable hall space that is not available for production or incoming goods. Foldable containers can be stored in stacks on a fraction of the required floor space.

Conclusion: Every return trip that is eliminated saves direct transportation costs (fuel, travel time, driver compensation). Every square meter of storage space that is freed up reduces operating costs. Foldable reusable containers are not a convenience – they are a cost issue. More about our systems: ThorPak product overview.

Comparison of folding and collapsible large load carriers

Not every collapsible container is suitable for every application. The following table compares the most important systems according to area of application, recyclability and empties costs:

The Poka-Yoke closing system enables folding and opening without a prescribed folding sequence – one person is enough. The all-round forklift collision protection protects the container even when stacked with a forklift truck.

Technical features of the ThorPak Quattro:

• • Volume reduction: up to 75 % compared to the assembled state
  • External dimensions reference: 4,000 × 1,200 mm (when folded)
  • Poka-yoke closing mechanism: easy opening and closing, no folding sequence
  • All-round forklift collision protection
  • Lightweight lid included
  • Individual height of the storage space can be adjusted (no separate empties ring)
  • Options: Textile, foam and plastic compartments; several compartment levels; printable; steel-reinforced; stackable

With a 75% reduction in volume, this means that instead of four truck journeys for the return transport of empties, one is enough: ThorPak Quattro – details and individual sizes.

Plastic pallet becomes a transport container

In practice, many companies rely on mixed systems: a Euro plastic pallet or wooden pallet serves as the base element, on which a foldable KLT superstructure is stacked. This modular principle makes it possible to continue using existing pallet infrastructure – and still switch to foldable containers.

The ThorPak R-FSC and RL-FSC collapsible boxes are designed for exactly this use. With the composite base option (R-FSC), the containers stack securely and space-savingly on standard Euro pallets (1,208 mm). The containers are based on the VDA 4500 external dimensions (300×200, 400×300, 600×400 mm) so that they fit seamlessly into existing conveyor and shelving systems.

Practical example: 20 ThorPak R-FSC 6415F containers take up a full 1,208 pallet (PU/1208: 20 units). The same 20 containers fit on less than half the stack height when folded – the return pallet now carries 48 units instead of 20 (PU/1208 folded: 48 units). This means that 2.4 times more empty containers are transported per pallet on the return journey.

R-FSC and RL-FSC are also available in an ESD version for applications with particularly high demands on dimensional stability and electrostatic discharge (ESD). Product page: ThorPak RL-FSC – Folding box with extended dimensional program.

ROI calculation: When is the changeover worthwhile?

The question of whether foldable reusable containers pay off can be answered with a few key figures. The decisive factors are: Number of return transports per year, costs per trip, current container stock and empties storage costs.

The following example is based on a medium-sized production company with 52 return trips per year (weekly rhythm), travel costs of €350 per trip and a container requirement of 500 units of ThorPak R-FSC 6415F:

Practical example: Saving empties space with ThorPak FSC

An automotive supplier uses ThorPak R-FSC 6415F in its weekly KLT cycle. Initial situation: 480 units have to be transported regularly from assembly back to the central warehouse.

When assembled, 480 R-FSC 6415F (external dimensions 600×400×147.5 mm) occupy exactly 24 Euro pallets (PU/1208 assembled: 20 units). On the return transport truck with 33 pallet spaces, this means: one complete truck journey, loading space utilization of a good 70 %.

When folded, the figures change significantly: PU/1208 when folded: 48 units. 480 units fit on 10 pallets. The return transport only requires a third of the original loading capacity. If the truck is moving anyway, the remaining 23 pallet spaces are used for other goods – the proportion of empty runs is reduced to almost zero.

Storage space effect: The 24 pallets of empties storage space are reduced to 10. 14 pallet spaces that are freed up can be used for finished goods or raw materials.