This story originally appeared in the December 2025 issue of Modern Materials Handling.
Innovations in Tote and Container Design: Meeting the Demands of Modern Warehousing
As warehouse and distribution center (DC) operations evolve, the design and functionality of totes and containers are also progressing to meet new challenges. The market is gravitating toward products that integrate seamlessly with automation, promote sustainability, and enhance operational efficiency. Below are six pivotal trends redefining the next generation of totes and containers.
1. Automation-Ready Design
With the rise of automation in warehouses, the functionality of totes and containers must align with these advanced systems. According to Breanna Herbert, senior product manager at ORBIS Corp, organizations are heavily investing in automation and robotics, necessitating packaging solutions that can keep pace.
“Companies seek features like slots for vertical lifting, dimensional precision, and flat surfaces for easy scanning,” Herbert explains. The consistency of reusable totes is crucial for smooth operation throughout conveyors and robotic systems, allowing for efficient shipping and handling. Minor flaws in packaging can lead to operational delays, making standardization in containers essential.
2. Customization in Container Design
As the landscape of warehouse automation becomes more varied, a one-size-fits-all approach to packaging is becoming obsolete. Green at MDI notes that organizations are rapidly adopting various automation technologies, leading to a demand for tailored container solutions.
“We are engineering unique containers to fit specific automated systems and products,” Green states, highlighting the importance of customization to prevent operational hiccups. Custom-designed totes allow for seamless operation across various automation types, enhancing efficiency and meeting specific operational needs.
3. Single Container Efficiency
An example from a leading athletic footwear company showcases how the use of a single type of tote throughout the entire processing system can optimize operations. Flexcon’s molded plastic totes are used from order placement to shipment without any need for repacking.
Cole Beckerman, marketing manager at Flexcon, describes this integrated approach as emblematic of how modern warehouses aim to streamline workflows. Using a single container type can greatly reduce downtime and improve compatibility across all systems, allowing for a more efficient workflow from order picking to packing.
4. Ergonomics and Durability Matter
Operators are increasingly seeking containers designed for durability and ergonomics. Green emphasizes that MDI’s customers prioritize longevity in their totes, allowing for extensive reuse which, in turn, boosts overall efficiency.
Before production commences, MDI engages clients with questions about product specifications and handling requirements. These consultations guide ergonomic decisions regarding handle placements and operational ease, thereby enhancing user experience and reducing repetitive motion injuries.
5. Innovative Use of Lower-Level Storage
Creative strategies are emerging for utilizing lower storage spaces effectively. Beckerman notes that many warehouses are now filling lower racking levels with bins instead of investing in new shelving systems. This strategy maximizes storage space and enhances accessibility, allowing workers to retrieve items quickly and efficiently, which is vital in fast-paced environments.
“The idea is to make every cubic foot usable,” Beckerman adds, underscoring how even small layout adjustments can yield significant efficiency gains without hefty expenses.
6. Sustainability and Regulatory Compliance in Packaging
The ongoing evolution of reusable packaging reflects a growing balance between sustainability and performance. Herbert highlights a rising demand for higher levels of recycled content in packaging without compromising durability.
With new regulations such as the Packaging and Packaging Waste Regulation (PPWR) influencing industry practices, companies are compelled to design packaging that meets not just current needs but anticipates future compliance standards.
“The goal is not only to fulfill regulatory requirements but to excel in sustainability,” Herbert concludes, noting that as more manufacturers embrace greener practices, the conversation will shift from compliance to innovation.
As the landscape of warehouse and DC operations continues to evolve, the design of totes and containers will play a critical role in enhancing efficiency, sustainability, and overall operational performance.
