PP BOX & FLC · RETURNABLE PACKAGING

Packaging designed to come back.

Reusable PP boxes and 1-tonne Foldable Large Containers for the OEMs and distributors who are done with single-use. Engineered to replace corrugated and wooden crates — and to pay for themselves inside the first programme.

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80+Uses per PP box
1 tonneFLC payload
3000 GSMPP sleeve
ISO 9001:2015Certified
Blue reusable PP boxes and Foldable Large Containers in AICPL's despatch bay
What we do

Two returnable systems. One supplier.

AICPL manufactures two complementary returnable-packaging formats — reusable PP boxes for shop-floor and OEM transit, and Foldable Large Containers (FLCs) for 1-tonne industrial loads. Both are built around the same principle: packaging that keeps protecting components long after a single trip.

Our returnable formats replace corrugated outers, wooden crates and one-way plastic trays with containers designed for 80+ cycles.

ISO 9001:2015 Fully customisable Closed-loop Sustainable
Packaging formats

Our two returnable formats

01
PP BOX

The shop-floor workhorse

Lightweight, water- and chemical-resistant polypropylene boxes built for 80+ reuse cycles. Stack cleanly on pallets, resist humidity and shop-floor abuse, and refurbishable in-house when they finally wear.

  • Reusable 80+ times — in-house refurbishment extends life further (based on use)
  • Fully customisable: size, wall thickness, strength and colour
  • Antistatic PP options for sensitive electronic components
  • Stackable and nestable designs
  • Printed and colour-coded variants for cell-level identification
02
FLC · 1-TONNE SYSTEM

Foldable Large Containers

A complete returnable transit system for large or heavy components — a steel pallet base with a collapsible PP sleeve on top. Supports 1-tonne load per layer (two-layer system). Folds flat on the return leg for compact return-freight by your logistics team.

  • Complete system supports 1-tonne payload
  • PP sleeve up to 3000 GSM, with or without internal partitions
  • Fully customisable size, strength and colour
  • Folds flat for return — a fraction of stacked height
  • Replaces wooden crates, one-way cartons and single-use plastic trays
Where returnable formats work

Built for returnable supply chains.

Returnable PP boxes and FLCs for automotive component transit
01

Automotive component transit

  • Returnable loops between OEMs and Tier-1 suppliers
  • Cell-coded PP boxes for part-number-level identification
  • FLCs for engine, transmission and heavy-assembly transport
  • Customers include LEAP India and Belrise
Foldable large containers for heavy industrial components
02

Heavy-component & industrial transport

  • FLC systems for 1-tonne industrial equipment, castings and assemblies
  • Metal pallet thicknesses selected to match component weight profile
  • Metal pallet options: 3 mm · 4 mm · 5 mm · 6 mm sheet thickness
  • Customers include Liebherr, Clad Metal and Boxtron
Reusable PP boxes moving parts through a warehouse and shop floor
03

Warehouse & shop-floor logistics

  • PP boxes for internal storage, pick-and-pack and shop-floor movement
  • Stackable, nestable, printed and traceable
  • Reduces damage, speeds up handling, cuts cardboard rotation
Antistatic PP packaging for electronics and ESD-sensitive components
04

Electronics & ESD-sensitive

  • Antistatic PP box options for PCB, LED and cable transport
  • Combines returnable economics with ESD protection
  • Custom cavity inserts available via our thermoforming division
Our process

From one-way to returnable — in six steps.

  1. 01

    Audit

    Share your current packaging spec (carton, crate, tray) and your logistics loop.

  2. 02

    Design

    We propose the right returnable format (PP box, FLC or both), with cell geometry tuned to your component.

  3. 03

    Model

    We build the cost model: cost per trip, break-even cycle count, freight savings.

  4. 04

    Trial

    Pilot batch manufactured and despatched for validation in your actual logistics loop.

  5. 05

    Scale

    Full programme manufactured and despatched to your schedule, with repeat orders triggered by your replenishment plan.

  6. 06

    Supply & refurbish

    Ongoing supply of new containers. Damaged units sent back to us can be assessed and refurbished to extend programme life.

Product catalogue

See the formats that could replace your current packaging.

Download our 2026-27 Capability Catalogue — PP box range, FLC specifications, cost-per-trip modelling and application galleries.

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Start with your requirement

Still shipping in corrugated?

Share your current packaging spec and your logistics loop. Our team will come back with a returnable-format proposal, a cost-per-trip model, and a payback period — usually inside 48 hours.

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