This article will take an in-depth look at plastic crates.
The article will bring more detail on topics such as:
This section delves into the definition of plastic crates, explores their production methods, and examines their applications and benefits.
Plastic crates are specialized containers crafted for the effective transportation and storage of various goods. Constructed from either complete or partial plastic materials, they are noted for their robust durability. Although these crates may be priced higher than their wooden or cardboard counterparts, their extended lifespan and resilience make the investment worthwhile.
Typically, plastic crates are fabricated from high-density polyethylene (HDPE) or polypropylene (PP). HDPE is praised for excellent impact resistance and its ability to withstand UV degradation, while PP is admired for superior scratch resistance. To further boost these materials' durability, antioxidants and UV protectants can be incorporated during production.
The choice of manufacturing process for forming plastic crates is influenced by design and shape considerations. Each crate type is ideally produced by a specific fabrication technique. Below are some widely utilized methods for making plastic crates.
Injection molding is a process where molten plastic is injected into a secured mold or chamber, following three primary stages:
A reciprocating screw extruder is often utilized in mixing and kneading materials, channeling the prepared plastic into a mold. To shape the product, the mold crafted must feature specific attributes, usually split into two halves; one fixed and the other movable for product release. Multiple channels in the mold allow plastic filling, air venting, and overflow management.
Traditional injection molding has limitations and is less suited for crafting single-sided containers like tubs, pails, and bowls, or closed hollow products like bottles. Instead, gas-assisted injection molding is applied. Introducing inert gas fills a partially molded space, mitigating reactions and facilitating a hollow mold result.
Blow molding forms plastic containers by expanding softened plastic within a mold. Key steps include:
Similar to injection molding, blow molding uses screw extruders for adding, mixing, and heating plastic raw materials. In forming the preform, two types exist:
This method involves extruding a hollow tube, shaping it at an end within a mold.
Unlike extrusion, injection involves injecting plastic into a mold with an air core. Both methods rely on air to form plastic against the mold walls.
Injection molding is particularly favored for making plastic crates, whereas extrusion molding is ideal for crafting other hollow items like water containers, bottles, or storage tanks.
Rotational molding, or "roto molding," is a plastic casting method used for creating hollow, seamless items. Unlike blow molding, which uses pressure, rotational molding evenly spreads molten plastic inside the mold during rotation. The essential steps are:
Varieties of rotational molding equipment exist, differing in mold layouts, numbers, and rotational techniques during heating. Notable types include turret, clamshell, and shuttle machines.
The lack of high pressure in rotational molding makes it cost-effective for molds and suitable for larger items. The process can also produce double-walled crates without extra steps. Products often made include agricultural tanks, drums, bins, and insulation boxes.
Thermoforming involves heating thin plastic sheets to shaping temperature and stretching them over a mold. This secondary forming method uses pre-produced plastic sheets or films from extrusion or calendaring, involving steps like:
Thermoforming comprises methods like vacuum, mechanical, pressure, and twin sheet forming, each using different forces to shape the plastic. Vacuum, pressure, and twin sheet forming employ compressed air, whereas mechanical forming uses dies for shaping.
Thermoforming limits its application to thin-walled products, yet faces issues like inconsistent thickness, warp, and webbing, making it unsuitable for rigid container production.
Thermoformed items often include single-use containers for pharmaceuticals and food, like disposable cups, trays, or clamshell packaging.
Compression molding crafts plastic by pressing resin between molds, particularly for large thermosetting products. Essential steps in compression molding include:
Typically involving downward compression, presses can also close from below. Internal heating elements in molds soften the plastic and enable shape flow while simultaneously curing the plastic. During curing, gases may form and are removed in a degassing stage.
Compression molding is advantageous for designs incorporating fiber reinforcements, such as glass or carbon added during pre-forming. While similar to injection molding using two-part molds, it’s generally limited to open-sided containers. Items such as large bins, trays, and caps are typical examples.
Plastic crates are structured primarily in open or closed configurations. Closed crates feature detachable or hinged lids, while open ones are lid-free with grids for visible contents. Industries like delivery and food services frequently use these crates for items such as dairy, bread, drinks, meats, and seafood.
In storage or warehousing environments, plastic crates are vital for organizing, storing, and transporting goods. With handles for ease of handling, they are stackable or nestable to maximize space efficiency and come in myriad shapes, sizes, and colors designed for temperature resilience, weight handling, and impact resistance.
Creating plastic crates involves injecting plastic in molds, transforming raw material into functional products. The process starts with raw plastics fed into a hopper and channeled by rotating screws, liquefying it for molding.
The mold cavity shapes the plastic into the final design, and post-injection, the material cools and hardens under controlled conditions. Inspections for imperfections follow, with potential further processing before delivery.
Molds can bear custom imprints or logos through projecting letters in the mold. Generally, High-Density Polyethylene (HDPE) is the preferred material due to its robust thermoplastic properties utilized in crate manufacturing.
The advent of plastic crates has resolved numerous issues related to the use of wooden and cardboard crates for storing, handling, and transporting goods. As durable, reusable packaging solutions, plastic crates are available in a variety of sizes, styles, and configurations suited for multiple supply chain applications—including food distribution, agriculture, pharmaceuticals, and manufacturing logistics. Plastic crates offer superior strength, hygiene, and efficiency over traditional materials. Customers can select the optimal crate type and quality based on requirements such as load capacity, ventilation, stackability, and compatibility with automated material handling systems.
In this chapter, we will explore the various orientations and types of plastic crates, and examine how each design supports diverse industrial storage and transportation needs.
Plastic crates come in several stacking orientations, such as stack-nest crates, stacking crates, and collapsible plastic crates. These key differences, particularly in nesting and collapsibility, play a critical role when transporting empty crates—directly impacting logistics efficiency and transportation costs. Choosing the right orientation improves load optimization and minimizes return shipping expenses for industries relying on high crate turnover.
Among plastic crates, collapsible crates are the most expensive to purchase due to their advanced engineering and space-saving features, followed by stack-nest crates, with stacking crates being the most cost-effective option. Collapsible designs are ideal for maximizing storage density and minimizing return freight space, making them increasingly popular in high-volume distribution environments prioritizing sustainability and cost reductions.
These stacking crates feature a square or rectangular design with rounded corners, allowing for efficient use of vertical space by safely stacking crates on top of one another. Depending on dimensions, stackable crates can significantly outperform loose break bulk in maximizing truckload and warehouse utilization. The rigidity and modularity of stacking plastic crates improve load security and compatibility with automated storage and retrieval systems (ASRS).
While stacking crates have a rigid, durable design, further space can be saved on reverse logistics trips by nesting one crate inside two others or overlapping during stacking. Design elements such as rim gaps facilitate easier handling and transportation after delivery, optimizing the total cost of ownership for distribution networks.
Stack-nest crates are available with a variety of industry-specific modifications, including integrated swing bars, hinged covers, and 180-degree stacking features for selective access and improved warehouse operations. These LSI features make stack-nest crates ideal for industries seeking flexible, multipurpose distribution containers compatible with both manual and automated warehouse equipment.
The internal volume of a stack-nest crate is reduced compared to a square crate due to its vertically tapered shape, but effective loading space may be higher in multi-crate configurations. For example, five nested crates can occupy the same cubic space as two stacked crates of similar size with a swing bar design. Swing bars enable quick conversion from nesting to stacking mode: a swing bar is moved over the crate rim to support the next crate during stacking. This innovative design maximizes operational flexibility for warehouse managers and retailers.
The stack crate is somewhat stronger than the stack-nest crate because its bar rests on the corners, whereas for the stack-nest crate, the bar rests along the long side. Swing bars are positioned 1 to 2 cm below the rim, facilitating secure, easy stacking. For efficient stacking, crate alignment within this rim is essential. Some crate designs incorporate bottom-side features specifically to accommodate the swing bar.
Stack-nest crates can be fitted with two cover parts that close the crate and allow another crate to be stacked on top. This cover greatly improves product security and helps prevent loss or pilferage—crucial benefits for industries handling high-value goods. Plastic crates with secure covers are generally up to 50 percent more expensive than open designs, reflecting the added value of tamper-evidence and safe stacking for the logistics sector.
The box can be both stacked and nested by rotating it 180 degrees, enabled by built-in supports inside the crate. While these supports consume additional space, they enable flexible container management in warehouses requiring frequent access and rapid restocking. A collapsible crate uses hinged sides (plastic or metal) for even greater space-saving benefits and streamlined reverse logistics.
Although collapsible plastic crates save significant space when folded and feature an ergonomic, contemporary design, they are not always favored in trade due to higher initial purchase costs. However, companies focused on cost-per-trip, sustainability, and space optimization frequently choose collapsible crate solutions for bulk transportation and seasonal storage.
Below are some of the most commonly used types of plastic crates for storage, packaging, and shipping across various industries.
These standard-duty crates are designed for a wide range of basic storage applications and are available in multiple shapes, colors, and sizes. They are most commonly used in grocery distribution for the protection and transport of fragile items, such as fruits and vegetables. Returnable plastic crates facilitate grocery supply chains: they fold flat for inbound logistics and serve as rigid containers for outbound deliveries. Their modular design allows for a standard footprint and multiple stack heights, accommodating perishables, and optimizing pallet unit loads. Regular plastic crates are a cornerstone of modern food supply logistics, supporting intermodal transportation between growers, wholesalers, and supermarkets worldwide.
Ventilated crates are primarily used for the storage and distribution of food items, produce, and vegetables. Available in fully ventilated and nestable designs, these crates support airflow, temperature control, and freshness, which is critical in the cold chain for agriculture and food processing. Specialized options, such as dairy crates—crafted from durable, food-grade polyethylene—are custom-engineered for the rigorous demands of the dairy industry. They are robust enough to endure automated stacking, sterilization, rapid temperature shifts, and high-pressure washing.
The unmatched durability and hygiene offered by ventilated plastic crates ensure compliance with safety standards and best practices in material handling. Compared to wooden or cardboard crates, plastic variants offer enhanced resistance to moisture, cleaning chemicals, and the demands of automated processing lines—making them ideal for the food, beverage, and pharmaceutical industries.
High-quality closed plastic crates are available in many sizes and shapes suitable for secure storage and transport of sensitive goods—including fish, seafood, and perishables in the fishing industry. Used extensively for transporting catches from boats to holding tanks and processors, these crates are favored for their smooth surfaces, superior hygiene, and ease of cleaning. Closed crates also prevent leaks, contamination, and dehydration of fresh products. Their ergonomic handles, absence of nails or splinters, and standardized closure mechanisms minimize handling risks and improve operator efficiency, addressing limitations commonly found in wooden crates.
6040 plastic crates (measuring 600 mm long by 400 mm wide) are a popular industry standard, particularly in Europe and for automated warehouses. Their modular size allows for seamless compatibility with European and international pallets, conveyor systems, and shelving units, making 6040 crates a go-to solution in supply chain and logistics operations seeking streamlined, repeatable packaging options.
Large-sized or jumbo plastic crates are engineered for the storage and transportation of heavy or oversized items, such as bulk agricultural products, industrial parts, or automotive components. Their enhanced structural strength, reinforced corners, and high load capacities cater to applications demanding superior durability and stacking performance.
Designed for niche industrial or commercial use, special purpose plastic crates come with custom measurements, inserts, or reinforcement for applications such as poultry transport, document archiving, bread delivery, electronics packaging, and medical supply distribution. These custom crates help companies achieve higher operational efficiency, regulatory compliance, and protection for unique products during every stage of the supply chain.
Plastic crates can be compared to wooden crates in the following critical aspects relevant to modern logistics and supply chain management:
Plastic crates provide safer handling than wooden crates due to their ergonomic design, lighter weight, and smooth, splinter-free surfaces. Their precise manufacturing also reduces sharp edges or exposed fasteners, minimizing workplace injuries. Reduced weight lowers risk of strain or injury for workers, while facilitating compliance with occupational safety standards.
Due to their ability to nest and stack efficiently, plastic crates deliver significant space savings in warehouses, transport vehicles, and storage facilities. This space optimization not only lowers shipping and warehousing costs but also minimizes environmental impact by reducing the number of return trips required for empty container retrieval.
Plastic crates offer consistent sizing, a broad selection of designs, and lighter weight—making them easier to maneuver, automate, and transport than wooden alternatives. These features benefit supply chain automation, conveyor handling, and rapid order picking, providing speed and reliability in high-throughput distribution environments.
Plastic crates are engineered to withstand a wide range of operating temperatures (from -22°C to +60°C), high UV exposure, and adverse environmental conditions without cracking or warping. In contrast, wooden crates are vulnerable to damage from humidity, mold, pests, and even minor temperature changes. This makes plastic containers the preferred choice for outdoor logistics, cross-border shipping, and refrigerated transport.
The non-porous, smooth surfaces of plastic crates make them far easier to clean, sanitize, and maintain, ensuring compliance with strict hygiene regulations in sectors like agriculture, grocery distribution, food processing, pharmaceuticals, and healthcare supply chains. They withstand steam, hot water, and chemical disinfectants—whereas wooden crates are permanently damaged by such cleaning methods and cannot be reliably sanitized for reuse.
This chapter will explore the applications and advantages of plastic crates.
The applications of plastic crates include:
In the dairy industry, milk crates serve an extremely important means to supply milk cans and packets across cities and towns. They are also important and efficient in shipping milk across long distances, holding them firmly and avoiding spillage. While compared to wooden and cardboard crates used in the prior years, plastic crates have now become an increasingly gained market due to their lightweight and resilient structures. Typically made of polyethylene (PE), plastic milk crates are resistant to repeated washing and ensure more hygiene in the supply process.
Plastic crates play a crucial role in the agriculture industry, providing a hygienic and efficient method for transporting goods. They are preferred over traditional wooden and cardboard crates due to their resistance to fungal growth. As a result, plastic crates are increasingly chosen for transporting agricultural produce, soil, and seeds on a large scale. Additionally, plastic crates withstand extreme weather conditions, ensuring the secure transport of perishable agricultural products. Their durability and hygiene benefits make plastic crates an essential component in the supply chain for agricultural products, enhancing efficiency and safety.
In the fisheries industry, plastic crates, fish tubs, and ice boxes are essential for preserving fish quality during transport. These crates are poor conductors of heat and are resistant to rain, heat, and harsh weather conditions, effectively protecting the ice within from melting and keeping the fish fresh over long distances. Additionally, plastic crates are easier to clean compared to those made from other materials, ensuring better hygiene. This ease of cleaning is crucial for maintaining hygiene and preventing rust, making plastic containers the preferred choice for storing and transporting fish.
Transporting fruits and vegetables over long distances requires careful handling and hygiene, as these products are perishable and sensitive to harsh weather conditions. Plastic crates are a popular choice for such transport due to their compact design and resistance to external factors. A wide variety of fruits and vegetables are routinely transported in plastic crates from one location to another. During the process, these crates are often stored in built-in pallet storage systems before being further distributed to markets.
Another major domain that utilizes plastic crates is the grocery industry. They are used for storing and transporting grocery items and also assist customers in carrying items easily around supermarkets. These crates help in efficiently supplying packaged grocery items to the markets. The durability and resilience of plastic crates ensure the easy transportation of even bulky grocery items.
Plastic crates are containers used for moving or transporting goods from one point to the other. Plastic crates are found in a variety of configurations including collapsible plastic crates, stack nest plastic crates, etc. Due to their different configurations, each plastic crate has its own unique suitable application, for example the stack crate with cover can be sealed, preventing pilferage of produce. Therefore it is most suitable for use in the food industry where the food needs to be kept clean and safe. Plastic crates also offer many advantages such as being strong, rigid, and easy to clean. They also have disadvantages of damaging the produce with their rough surface. Therefore it is wise to consider the configuration and properties of the plastic material used when opting for a plastic crate.
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