Switching to reusable packaging often raises the same concern in companies: “Will this complicate our organization?”
It is a legitimate question. Logistics operations are already optimized, under pressure, and any change can seem risky.
However, transitioning to reusable does not require changing everything overnight. It can be done progressively, without disrupting existing flows.
Companies that succeed do not transform everything at once. They test, learn, and adjust.
In other words: they start small.
1. A simple and controlled process :
The key to a successful test lies in choosing the right starting point.
Rather than aiming for a global rollout, it is much more effective to identify a specific, limited, and well-defined flow.
These are often internal or regular flows:
- Transfers between two sites
- Deliveries to fixed points
- Circuits with few stakeholders
These flows have a major advantage: they are predictable. Volumes are known, frequencies are stable, and teams are already organized around these movements.
This is the ideal ground to test without disruption.
2. Integrating with the existing system :
A common mistake is trying to rethink the entire organization from the start. In reality, a test works better when it integrates into existing practices.
The objective is not to change everything, but to replace one specific element:
- A type of packaging
- A specific use
- An identified friction point
The same teams, same schedules, and same circuits can be maintained.
--> Only the packaging changes.
This approach reduces resistance and allows focus on what matters: observing what works.
Some adjustments are needed: replacing bins with collection bins and adding some information to encourage the use of the new packaging and prevent a return to old habits.
3. A limited volume:
A test does not need to be perfect. It needs to be manageable.
Starting with a limited volume allows you to:
- Limit risks
- Track packaging precisely
- Quickly identify improvement areas
This can represent:
- Part of the shipments
- A product range
- A defined number of rotations
What matters is not the scale of the test, but its clarity.
4. Observe before optimizing :
During the first weeks, the goal is not to reach maximum performance.
It is about observing:
- How teams use the packaging
- Where constraints appear
- How the return process works
These observations are essential. They allow the system to be adjusted:
- Improve the design
- Simplify actions
- Clarify responsibilities
- adapt the packaging labelling
Field experience always provides the best insights.
5. Involve the teams :
A test does not succeed only on paper.
It is the field teams who make the system work daily.
Involving them from the beginning allows you to:
- Collect concrete feedback
- Identify invisible problems upstream
- Facilitate adoption
When a project is co-built, it becomes simpler, more efficient, and more sustainable.
6. Structure the feedback :
The most sensitive point remains the return of packaging.
But in a test, there is no need to implement a complex system.
A simple loop is enough:
- Return during next deliveries
- Grouping at an identified point
- Clear responsibility
The objective is to validate that the return works, not to perfect it immediately.
7. Measure to decide :
A test only has value if it helps make a decision.
It is therefore essential to track a few simple indicators:
- Number of rotations
- Return rate
- Team feedback
- Operational impacts
These elements allow you to assess:
- Model viability
- Necessary adjustments
- Deployment potential
Without measurement, there is no learning.
Conclusion : test without risk, learn quickly:
Testing reusable solutions does not mean disrupting your organization.
On the contrary, it is a progressive, pragmatic approach that builds on existing systems.
Companies that succeed are those that:
- Start with a simple workflow
- Limit the scope
- Observe the field
- Adjust before scaling
Reusable is not a risky bet.
It is a system built step by step.
And generally, the first results come faster than expected.
At Loopipak, we structure these testing phases with companies to secure the transition: flow selection, adapted design, field pilot, and result measurement through profitability studies, life cycle analysis, and operational metrics.
Because the best way to convince...
Is to test and measure.
7 steps to test reusable packaging in internal logistics without disrupting flows