How to automate returnable transport packaging handling

Returnable transport packaging handling can be automated across every stage of the process, from receiving and destacking through washing, buffer storage, and dispatch to filling lines. The technology is mature, widely deployed in food production and logistics, and capable of handling between 500 and 3,000 crates per hour depending on the system configuration. Nekos is a specialist in automated plastic crate and RTP handling systems, with more than 60 years of experience designing and delivering integrated solutions for food producers and logistics operators across Europe. The sections below answer the most common questions production managers ask before committing to an automation project.

What types of returnable transport packaging can be automated?

Most standard plastic crates, trays, and totes used in food production, retail logistics, and industrial distribution can be handled by automated RTP systems. The key requirements are consistent outer dimensions and sufficient structural rigidity to withstand mechanical handling. Stackable crates with standardised footprints are the most straightforward to automate, but systems can also be configured for nestable trays and lidded containers.

In practice, the vast majority of returnable transport packaging in food and logistics operations falls into the automatable category. This includes dairy crates, bread trays, produce boxes, meat totes, and beverage crates. Mixed fleets with several crate types can be handled on the same line using sensor-based detection and adjustable guides, though the more uniform your packaging pool, the simpler and more cost-effective the system design.

What processes in RTP handling can be automated?

The core processes that can be automated in a plastic crate handling system are receiving and infeed, destacking, washing, buffer storage, restacking, and outfeed to filling or dispatch points. Each of these steps can be automated independently or integrated into a single continuous flow, depending on your facility layout and throughput requirements.

A fully integrated RTP handling automation line typically works as follows:

1. Receiving: Stacks of returned crates are fed into the system from pallets, roll cages, or directly from the floor using infeed conveyors with stack-height monitoring.
2. Destacking: An automatic destacker separates individual crates from the stack and places them onto a single-layer conveyor.
3. Washing: Crates pass through an industrial washing machine that pre-washes, washes, rinses, and dries them hygienically.
4. Buffer storage: Clean crates are restacked and held in a buffer system to balance flow between washing output and filling line demand.
5. Outfeed to filling: Crates are destacked again at the filling station and presented to operators or downstream automation at the correct pace.

Conveyor technology connects each stage. Depending on the application, roller, belt, slat, or modular belt conveyors are selected to match the crate type, load, and hygiene requirements.

How does automated crate destacking and stacking work?

Automated crate destacking works by mechanically gripping or supporting a stack of crates, lifting the upper portion, and releasing the bottom crate onto a conveyor. The process then repeats until the stack is empty. Stacking is the reverse: individual crates arriving on a conveyor are lifted and accumulated into a growing stack that is then released as a complete unit.

The mechanical principle varies by manufacturer and crate type. The most common approach uses side-gripping arms or lifting forks that engage the second crate from the bottom, holding the rest of the stack suspended while the lowest crate moves onto the outfeed conveyor. The cycle repeats at high speed, enabling throughput rates from around 500 crates per hour in compact systems up to 3,000 crates per hour in high-capacity industrial installations.

Stacking systems work on the same principle in reverse, accumulating crates on a rising platform or using a gripping mechanism to build the stack from below. The finished stack is then conveyed to storage or dispatch. Both destacking and stacking can be integrated with stack-height sensors and PLC controls to regulate flow automatically and flag jams or empty infeed conditions without manual intervention.

What is the role of buffer storage in an automated RTP system?

Buffer storage in an automated RTP system acts as a flow regulator between processes that run at different speeds or on different schedules. Without a buffer, a mismatch between washing output and filling line demand causes either starvation at the filling point or a backlog at the washer. A well-sized buffer absorbs these fluctuations and keeps both upstream and downstream processes running at their optimal rates.

In practice, returned crates rarely arrive in a smooth, continuous flow. Deliveries come in batches, washing cycles have fixed throughput, and filling lines have variable demand throughout the shift. Buffer storage decouples these rhythms. It also provides resilience: if the washer goes offline briefly for maintenance, the filling line can continue drawing from the buffer rather than stopping immediately.

Our LT Storage system is designed specifically for this role. It places stacks of clean crates in sequential rows directly on the warehouse floor, maximising floor area utilisation without requiring racking or elevated structures. The system operates in spaces as low as 650 mm above stack height, making it practical even in facilities with structural constraints. Because it is the most cost-efficient crate storage solution of its kind, it delivers strong buffer capacity without disproportionate capital cost.

How do you calculate the ROI of automating RTP handling?

The ROI of RTP handling automation is calculated by comparing the total cost of the automated system over its operational life against the measurable savings it generates, primarily in labour, reduced product damage, improved throughput, and lower error rates. In most food production environments, the payback period falls between two and five years, though high-volume operations with significant manual labour costs often see returns within two years.

To build a credible ROI calculation, work through these cost and benefit categories:

• Labour savings: Count the hours currently spent on manual crate handling per shift, multiply by your fully loaded labour cost, and project this across the year. Include recruitment and training costs associated with high-turnover manual roles.
• Throughput gain: Estimate the additional production capacity unlocked by removing bottlenecks. Even a modest increase in line utilisation can represent significant revenue at scale.
• Reduced damage and loss: Manual handling causes more crate damage and product contamination events than automated systems. Quantify your current damage rate and apply a realistic reduction factor.
• System cost: Include capital investment, installation, commissioning, and ongoing maintenance. A realistic maintenance budget for a well-designed system is low relative to the labour costs it replaces.
• Residual value: Quality automation systems have long operational lives, often 15 to 20 years with proper maintenance, which spreads the capital cost further.

Present your calculation in terms of net present value and payback period rather than simple cost comparison. This gives management the financial framing they need to approve capital investment with confidence.

What should you consider when choosing an RTP automation supplier?

When choosing a supplier for returnable packaging logistics automation, the most important factors are system integration capability, industry-specific experience, references in comparable operations, and the quality of after-sales service. A supplier who can design and deliver the full process, from infeed through washing, storage, and outfeed, reduces integration risk significantly compared to assembling a system from multiple vendors.

Evaluate potential suppliers against these criteria:

• End-to-end capability: Can they design, manufacture, and commission the complete handling line, or will you need to coordinate between multiple parties?
• Industry references: Do they have proven installations in food production or logistics environments with hygiene and throughput requirements similar to yours?
• Modular design: Can the system be expanded or reconfigured as your operation grows or changes? Rigid systems become expensive liabilities when production requirements shift.
• Factory acceptance testing: Reputable suppliers assemble and test the complete system at their facility before delivery. This catches problems before they become commissioning delays on your floor.
• Service and spare parts: Confirm that the supplier offers preventive maintenance contracts, rapid response for breakdowns, and long-term spare parts availability. A system that runs for 15 years needs a service partner who will still be there in year ten.
• Compliance documentation: All equipment should come with a declaration of conformity and meet applicable machinery directive requirements. Ask for this as a standard deliverable, not an afterthought.

We have built our reputation over more than 60 years on exactly these principles, supplying integrated plastic crate handling systems to food producers and logistics operators across Europe. Every system we deliver is assembled and test-run at our factory before it reaches your facility, so commissioning is fast and the risk of surprises is minimal. If you are planning an RTP automation project and want to discuss your specific throughput, crate fleet, or facility constraints with an experienced team, contact Nekos to start the conversation.