Case study #2

Situation:

A global food manufacturer, known for its extensive portfolio of household brands, had an existing reuse program where all gaylord totes were sent to another company for fumigation and reuse. However, after discussions and a closer examination of the process, something didn’t add up. The company needed a transparent and validated approach to ensure that the program was truly delivering financial and environmental value.

Task:

Audit the existing reuse program and determine whether a different approach could provide better financial, operational, and sustainability outcomes.

Action:

UsedCardboardBoxes (UCB) analyzed data and conducted a thorough audit of sample loads from the existing program. The audit uncovered discrepancies and revealed that the company was being taken advantage of, as the reported reuse rates and cost efficiency did not align with the actual numbers. UCB developed a new, optimized solution tailored to the company's operations:

• Complete Program Overhaul: The company switched to UCB, redirecting all unpacked Gaylord totes for processing, grading, and repurposing.

• Strict Quality Control & Sorting: Each tote is now inspected and graded at UCB facilities:

• Grade A (food-grade quality): Returned to the company for closed-loop reuse in its supply chain.

• Grade B (non-food-grade but still viable): Purchased by UCB and resold to secondary marketplaces, creating an additional revenue stream.

• Non-reusable totes: Properly recycled to ensure maximum landfill diversion.

• Integrated Technology & Transparency: UCB integrated its real-time tracking and reporting software directly into the company’s ERP system, providing instant visibility into every tote’s status, from collection to processing and resale.

• Expanded Sustainability Efforts: Beyond tote management, UCB has also begun working on broader recycling initiatives, enhancing the company’s overall waste reduction strategy.

Results:

Since implementing the new Gaylord Tote Reuse Program, the company has experienced substantial financial and sustainability benefits:

• Millions of dollars saved annually by reducing the need to purchase new Gaylord totes, leveraging reused ones instead.

• Millions of dollars earned annually from the resale of Grade B totes and recycling efforts.

• Dramatic increase in landfill diversion, with more totes repurposed instead of being wasted.

• Full visibility & control through real-time ERP integration, enabling precise tracking of every tote processed.

• 12+ years of sustained success, proving that a truly circular, sustainable approach delivers long-term environmental and financial gains.

By switching to UCB’s transparent and efficient reuse program, the company has not only cut waste and costs but has also created a scalable, data-driven sustainability initiative that continues to evolve and expand.