Rehrig Pacific's study on reusable packaging reveals significant productivity improvements and cost reductions in the supply chain for delivering small format beverages. Tests showed that using their reusable secondary packaging saved an average of 4 minutes and 51 seconds per delivery compared to traditional one-way packaging, amounting to substantial savings. Furthermore, the use of reusable packaging resulted in a zero trash footprint, enhanced sustainability, and boosted revenue through improved in-store marketing effectiveness.

1. HOW REUSABLE PACKAGING
OPTIMIZES PRODUCTIVITY
AND ELIMINATES WASTE

2. Rehrig Pacific, a logistics optimization
company, creates reusable packaging
solutions that reduce costs and eliminate
waste in supply chains.
In late July 2014, Rehrig Pacific conducted field
tests to evaluate delivery and merchandising
productivity at two stages in the DSD process.
Solutions designed by Rehrig Pacific to
improve beverage routing efficiencies at these
stages in the DSD process were compared to
an existing DSD method.
A set of tests assessed the time required
for a driver to merchandise beverages and
dispose of trash. The two different methods
analyzed were:
1. Disposable one-way packaging—
cardboard and shrink-wrap.
2. Reusable secondary packaging
from Rehrig Pacific including Retail
Ready Merchandisers.
OVERVIEW
To test and verify that
utilizing Rehrig Pacific’s
reusable secondary
packaging improves
driver productivity and
potentially reduces costs
associated with the
delivery of small format,
single-serve, immediate
consumption products.
PURPOSE
How Reusable Packaging Optimizes Productivity and Eliminates Waste | Case Study

3. 5:2510:16 4:28 1:46
Rehrig Pacific conducted time tests in July 2014 in
Southern California. The tests compared a distributor’s
existing delivery method—expendable one-way packaging,
to Rehrig Pacific’s reusable secondary packaging solution—
that included the use of Retail Ready Merchandisers. The
field test was designed to determine the length of time
required to merchandise Gatorade products into refrigerated
cases and dispose of all corrugate and shrink-wrap.
Four cases of 20 oz. Gatorade (24 units per case) and twelve cases of 28 oz.
Gatorade (15 units per case) were used in the time tests in order to gather
objective, scientifically comparable results.
METHODOLOGY
RESULTS Minutes to merchandise
Rehrig Pacific reusable packaging saved 4:51
In the 28 oz. Gatorade product time test, the
driver took 8:17 to remove shrink-wrap and
merchandise the product and an additional
1:59 to dispose of packaging, resulting in
a total time of 10:16. By contrast, utilizing
Rehrig Pacific’s reusable Gatorade Beverage Crates
took 5:14 to merchandise and only :11 to place
reusable shells in storage, for a total time of 5:25.
Using reusable packaging from Rehrig Pacific
reduced driver time by 4:51.
4:51 = $47,530,000
Four cases of 20 oz. Gatorade (24 units per case) and twelve cases of 28 oz.
Gatorade (15 units per case) were used in the time tests in order to gather objective,
scientifically comparable results.
Time Savings Result and
Substantial Cost Savings
Rehrig Pacific reusable packaging saved 2:42
The time savings for merchandising and the
disposal of packaging for the 20 oz. Gatorade
product were also significant. Traditional one-way
packaging took the driver 4:00 to merchandise and
another :28 to dispose of the trash. Reusable Gatorade
Beverage Crates took 1:35 to merchandise and :11 to
place shells in storage, for a total time of 1:46. Using
Rehrig Pacific reusable secondary packaging saved 2:42
of driver time. It is important to note that using Rehrig
Pacific reusable packaging created a zero trash footprint.
How Reusable Packaging Optimizes Productivity and Eliminates Waste | Case Study

4. CONCLUSION
The primary focus of the in-the-field
merchandising time test was to validate the
concept that reusable secondary packaging
would measurably improve productivity
in the delivery and merchandising of
small format, single-serve, immediate
consumption products.
There are additional benefits of reusable
Merchandiser crates for the C-Store.
Reusable secondary packaging eliminates
all costs related to one-way packaging
including the C-Stores disposal costs
(small format stores do not have bailers or
separate recycling containers so cardboard
and shrink wrap are almost never recycled),
enhances sustainability initiatives and
boosts revenue generation via proven
Sales Lift. Based on previous research
conducted by Rehrig Pacific in partnership
with Clemson University, unique secondary
packaging designed with on-message, brand
building color and graphics can enhance
brand awareness and increase purchase
intent when integrated into in-store
marketing campaigns.
Benefits of using secondary packaging can
also include fewer product touches (staging,
breakdown, hand trucking, merchandising,
etc.), reduced total delivery time per stop,
decreased labor hours per driver and lower
packaging related costs (plastic and corrugate).
Utilizing Rehrig Pacific reusable secondary
packaging creates significant value in
the supply chain by improving driver
productivity and reducing costs associated
with delivering small format, single-serve,
immediate consumption products.
Rehrig Pacific Company Corporate Headquarters:
4010 East 26th Street, Los Angeles, CA 90058
(800) 421-6244 · (323) 262-5145 · FAX: (323) 269-8506
Email: info@rehrigpacific.com
Web: www.rehrigpacific.com
How Reusable Packaging Optimizes Productivity and Eliminates Waste | Case Study