FedEx Corp. has introduced a design for reusable shipping boxes in B2B shipments, part of an effort to reduce packaging use and improve handling efficiency in certain distribution operations.
It developed the packaging system with reusable packaging provider Returnity. The companies seek to replace single-use corrugated boxes in shipments moving between facilities such as warehouses, stores and service locations.
FedEx provides transportation, logistics and ecommerce services through a global parcel network and reported approximately $90 billion in annual revenue. The company has said it aims to achieve carbon-neutral global operations by 2040.
Close to half of the Top 2000 retailers in North America use FedEx as a shipping carrier, according to Digital Commerce 360 data. The Top 2000 refers to North America’s largest online retailers by annual ecommerce sales. In 2025, 927 online retailers in the Top 2000 Database used FedEx as a shipping carrier.
How FedEx’s reusable shipping boxes could help B2B shipments
FedEx said the containers are collapsible and designed to move through its existing sorting and automation systems. Each box can carry shipments weighing up to 50 pounds. The companies designed the boxes for up to 50 shipment cycles before replacement.
The company said the packaging format may reduce packaging costs by as much as 30% per shipment cycle compared with single-use corrugated boxes. FedEx also estimates the reusable containers could reduce packaging-related carbon emissions by between 64% and 88% under typical conditions if companies return and reuse the boxes.
The companies designed the system for “closed-loop” shipping environments where companies can consistently return packaging to the sender. Examples include shipments from fulfillment centers to retail stores, transfers between distribution facilities and certain reverse-logistics operations.
“In collaboration with Returnity, we have created the first scalable reusable box solution for B2B customers, which is especially useful for our soft-goods shippers,” said Neil Gibson, senior vice president of global customer experience at FedEx.
FedEx said the system has been tested with several B2B shippers in North America. During those trials, the company said, participants reported faster unpacking and restocking, improved labor efficiency and lower product damage rates.
“FedEx made reuse make sense by building the business case, doing the work, and creating a model for how circular logistics can succeed at scale,” said Mike Newman, chief executive officer of Returnity.
The reusable packaging is currently available to FedEx customers in the United States. FedEx said it plans to expand the system to Australia and Europe.
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