7 Common Uses for Reusable Custom Cases

Reusable custom cases–made in a wide range of materials, appropriate for the purpose–are indispensable in a wide range of industries and professions. They keep essential tools of the trade readily accessible when needed—and protected from shock, moisture, dust and other damaging threats.

Following are seven examples of the more common ways custom manufactured cases are used in various industries and professions:

test tube casesSales: Professional sales representatives across a range of industries depend on sales cases wherever they go to make presentations to potential customers. Sales cases must look good, to make good impressions. And they have to protect a sales representative’s samples on the road, between sales calls, so they look their best and stay in good working order, presentation after presentation. Sales representatives also need custom reusable trade show cases that are easy to transport and provide excellent protection of expensive trade show displays.

medical custom caseMedical: Medical instruments and equipment are expensive. And they can be fragile and easily broken or taken out of calibration. That’s where custom designed medical cases are invaluable. They feature compartments specially designed to nest the equipment and protect it from damage  in transit. Foam inserts can be cut to exact dimensions to cradle the equipment from shock.

first aid casesFire and rescue: First responders depend on custom designed cases that are easy to carry when minutes and seconds are critical. And they need cases that stand up to their rugged working conditions, to protect the critical equipment inside.

Industrial: Service technicians in a wide range of industrial settings need tool and equipment cases that are easy to take with them, wherever they’re called–sometimes far above the factory floor. And that organize their tools so they’re easy to find and access, to speed repairs and reduce costly downtime.

Prosumer and professional electronics: Experienced amateurs and seasoned professionals expect custom cases that protect their investments in high quality photography, video or audio equipment–and provide plenty of well-organized room for all the needed gadgets that go with it.

Military: Military agencies and defense contractors use rugged custom military cases for a wide range of applications such as weapon transport cases, rackmount server cases and field communications equipment.

plastic case with foam liningShipping: Custom reusable shipping cases, designed for specific products, offer exceptional protection in transit while offering the added benefit that they can be used hundreds of times. In contrast, cardboard boxes or wooden shipping crates offer one-time use and less protection for contents than a custom shipping case. Over the long haul, custom shipping cases can save money in reduced product loss and expenditures for shipping containers.

In addition to making custom manufactured cases, Flexcon offers a wide range of standard cases made of various types of plastic, wood and metal for nearly any application. They are available with foam dunnage, locking latches, custom imprinting, velcro closures, ESD materials and more.

Contact a Flexcon sales representative today to learn more about our range of standard cases and our capability to design and manufacture custom cases for nearly any application you have.


The Advantages of Molded Stack Nest Totes and Bins Stack Up

stack nest totesReusable plastic totes and bins offer numerous advantages for warehousing and transporting products in open or closed loop systems as well as storing and organizing materials during work in progress in manufacturing assembly applications. And molded stack nest totes offer extra benefits, thanks to their unique design.

The bonuses of plastic molded stack nest totes are contained in their name. They’re designed to:

  • Stack atop each other to optimize space usage. They cube out well on 48 x 40 and 48 x 45 pallets.
  • Nest in each other when empty and turned 180°. Between uses, this saves valuable space for other production needs.

The Advantages of Molded Stack Nest Totes Go On and On

stack nest totesOn top of these pluses, stackable and nestable molded plastic containers provide many additional advantages over other alternatives such as corrugated cardboard trays and totes. These include:

  • Heavy-duty, durable construction that provides exceptionally long service life. Since they can be used hundreds of times, they deliver substantial cost-savings over the long haul, compared to other alternatives that must be replaced at greater frequency.
  • Ability to be recycled at the end of their lifecycle–and returned to productive use rather than entering the waste stream
  • Increased production efficiency in manufacturing facilities. They provide optimal organization of parts, prevent migration of parts, minimize part handling and help you take control of inventories,
  • Effective use in all types of pick-and-pack applications for order fulfillment. They simplify picking applications and can be stacked before orders are fully packed out and shipped.
  • Strong construction with industrial-grade polymers that resist rust, corrosion, moisture, most chemicals and impact. Plus, even when fully loaded, the durable walls of stackable and nestable bins and totes resist bending, retaining the containers’ shape and promoting efficient use of space and handling.
  • Optimal protection of parts and products, thanks to strong construction and design that reduces risk of part migration
  • Capability to be used in automated storage and retrieval systems, maximizing available cube for maximum efficiency
  • Pitched drain holes that enable water to drain out and prevent collapse of automated storage and retrieval systems when sprinklers are set off—a requirement of most insurance carriers
  • Availability in nine sizes and three standard colors—gray, blue and red. And Flexcon can customize stackable and nestable containers to your application requirements and color needs.
  • Made of material that meets USDA and FDA regulations for use in food processing
  • Made with textured bottoms for non-slip grip on conveyors and in transit
  • Optional clear label holder available for all nine sizes of totes for clear part identification
  • Optional lids available. Designed to snap on tightly and securely for optimal content protection
  • Optional drop-in inserts are available, customized to hold specific parts and products for optimal protection and efficiency of handling

stack nest totesAnd you’ll likely discover more advantages in many of your material handling applications. To learn more about how to put molded stack nest totes to work for you, contact a Flexcon sale representative today.


Vertical Lift Module Dividers: the Perfect Solution to Optimizing the Efficiency and Organization of Your Material Handling Systems

Plastic DividersDo you want to make the most of every cubic inch of your reusable plastic trays and corrugated plastic containers—and not waste a bit of space?  All while you neatly and perfectly organize your parts and products? If so, Flexcon’s Vertical Lift Module (VLM) dividers are the solution you’re looking for.

Flexcon’s plastic VLM dividers—the Perfect Divider™ system—increase capacity and efficiency of your material handling system by 35 percent. That’s just one of the many features and benefits of Flexcon VLM dividers. They serve nearly any application, as they’re available in 12 standard configurations and can be customized—at no additional cost—for your unique material handling needs.

Here’s a look at the many additional features and benefits of our reusable, recyclable, plastic VLM dividers:
Plastic Dividers

  • Cost and weigh half as much as traditional metal dividers, for easier handling in your budget and material handling systems
  • Increase the capacity of a tray or container because of their reduced weight
  • Enable you to organize your parts and products to greatly reduce picking errors
  • Customize to provide the perfect fit for a wide range of material handling systems—from plastic tubs, containers and trays to carousels and other automated storage and retrieval systems. They can even be used as dividers on carts. Plus, use your imagination to put them to work in organizing more than just organizing products and parts. They make excellent tool holders, for instance.
  • Assemble easily, taking just a fifth of the time of other dividers
  • Prevent cut hands and fingers during handling. Flexcon dividers have smooth, laser-cut, cauterized edges. Plus, they’re coated in an eight-layer process that gives them a smooth kitchen cabinet-grade finish.
  • Do their job quietly. They don’t rattle, like metal dividers do, when your material handling system is on the move.
  • Come in a range of standard colors. And we can make them in custom colors to suit your needs.
  • Offer you a choice of available accessories to accommodate a wider range of uses and to offer greater protection for certain items—such as bottom pads, dense foam pads and bin cup inserts
  • Offer you a 6″, 4″, 2″ and ¼” adjustability option

Sizes of Flexcon Vertical Lift Module dividers vary greatly, from 12″ to 120″ and heights of 1 ½” to 20″. To help find the best solution for your needs, request a quote or contact one of our expert Flexcon sales representatives.

And to help you in your decision process, we offer VLM literature and mini sample kits. Just ask for one.


8 Benefits of Postal Totes

postal totesDurable, returnable plastic postal totes and mail bins made by Flexcon are the answer for a full range of material handling needs -in addition to mail room use.

While they improve organization and efficiency of mail centers, they also help streamline organization of materials and products, from assembly operations to warehousing (including use in automated storage and retrieval systems) to shipping and handling and transport.

You can find a complete range of postal container solutions – mail bins, postal totes, flat trays, flat tubs and postal bins – by visiting Flexcon’s Postal Totes website. We offer them in a wide range of sizes, designs and colors to meet your complete needs for corrugated plastic containers.

postal toteOur USA-made returnable postal containers are available in a variety of colors – semi-clear, red, blue, green, black, white and yellow. This enables you to develop a color-coded system of organizing material handling and distribution. These postal containers can be used for collecting, sorting, organizing, warehousing and transporting materials and products.

Other key features and benefits of postal bins and mail trays include:

  • Made of tough, lightweight plastic for easy handling and long, dependable life. Providing extra strength for heavy loads, some bins feature welded seams and steel rod reinforcements.
  • Cut-out handles make carrying these corrugated plastic boxes and corrugated totes easy and ergonomic for your workforce
  • Plastic corrugated containers resist chemicals, water and impact, providing optimal protection of your materials and products
  • Smooth interior and exterior surfaces of the reusable plastic containers make them easy to clean
  • Made of plastic, they last for the long haul, making it easy on your budget. And these recyclable plastic containers are easy on the earth. Because they’re recyclable, these reusable containers don’t take up landfill space when they do come to the end of their lifecycle.
  • Similar sized corrugated plastic totes nest together. This saves you valuable space in your facility when they’re not in use.
  • Made to the same standards as USPS postal containers
  • Various available sizes of mail bins, postal totes, flat trays, flat tubs, postal bins and postal containers fit most standard carts for transport within your facility

postal toteFor more than 50 years, Flexcon has been the trusted supplier of durable, reusable and returnable plastic containers for a wide range of industries. Today we serve more than 75 percent of Fortune 500 companies. For more information about our postal containers and other corrugated plastic boxes and plastic corrugated containers and bins, contact a Flexcon sales representative today.

Straight-Wall Stack Totes Help You Make the Most of Every Cubic Inch of Space for Storage, Material Handling and Transport

Straight wall stackable toteAre you looking for a container that will help you make the most of your manufacturing, material handling, warehousing and cargo space? Straight-wall stack totes are likely what you’re looking for.

Their modular, space-saving design makes straight-wall stackable totes and containers an excellent choice for:

  • Closed or open loop material handling systems
  • Transport of materials or products from one facility to another
  • Transport within a facility
  • Warehousing
  • Storage of materials for In-process work
  • A wide range of industries, including light manufacturing, automotive, aerospace and electronics

These containers provide efficient cubing in trucks and on pallets to reduce your shipping costs. They are designed to cube on 48×40 and 48×45 pallets. And their straight sides allow you to fit more materials or products in each container.

Space Efficiency Is Just One of the Many Benefits of Straight-wall Totes

The space-saving design of straight-wall stack totes, however, is just the beginning of their features and benefits, which also include:

  • Ergonomic, built-in handles for easy, safe carrying
  • Sturdy injection-molded construction that resists impact, moisture and most chemicals
  • Reinforced sides and bottoms, which enhance product protection
  • Use in a wide range of temperatures, from -20˚ to 120˚F
  • Easy, sanitary cleaning due to solid sides and smooth inner walls
  • Durable construction that extends the life of containers to reduce your costs. They last for hundreds of uses, compared to the one-time use of corrugated cardboard containers. This is an advantage for the environment and your budget.
  • 100 percent recyclable, so when they do reach the end of their lifecycle, straight-wall stackable containers don’t end up in a landfill
  • Easily customizable for identification, which makes them ideal for close-looped material handling applications

Straight wall stackable toteOverall, straight-wall stack totes deliver cost savings and efficiency throughout your manufacturing, material handling, warehousing and shipping processes.

Flexcon offers a wide range of straight-wall stackable containers to meet your needs. And to extend the effectiveness of our containers for your applications, we can custom design divider inserts that perfectly fit your materials or products and protect them from damage.

To find the right straight-walled stackable containers for maximizing your shipping and storage needs, contact a Flexcon sales representative today.

Attached Lid Containers Keep a Lid on Loss and Damage to Your Precious Cargo–and Deliver Many Additional Benefits

Attached Lid ContainersReusable attached lid containers offer businesses like yours a load of features and benefits for storage and transport of materials and products.

You can find two of the key features and benefits right in the first four words of the above sentence:

  • Made of high quality plastic, these containers are reusable. That means they deliver high return on investment and reduced cost per transport, as each container provides you hundreds of uses, compared to the one-time use of a corrugated cardboard box. This also means they enable you to reduce waste and save landfill space.
  • As their name—attached lid container—implies, they feature attached lids. The lids open and close on metal hinges and can’t become separated from the containers. They save you from having to hunt for missing lids.

But this is only the beginning of the features and benefits of attached lid containers. Here’s the rest of the story:

  • Attached lid containers are excellent choices for closed-loop distribution, order picking and storage for a wide range of industries.
  • They are compatible with automated storage and retrieval systems. Their textured bottoms securely grip conveyor belts.
  • The attached lids interlock when closed. This protects your products and materials from loss, dust and damage.
  • Attached lid containers are made of sturdy, durable plastic that resists impact, moisture and most chemicals. Again, this prevents damage to your cargo. Pus it helps extend the lifecycle of the containers.
  • Featuring a lip around the top, these containers are designed to stack for optimal use of storage and cargo space.
  • When empty, they nest in each other, with the lids open. This saves space and shipping costs when the containers are returned empty.
  • They feature ergonomic handles for safe, easy lifting.
  • The interiors are easy to clean.
  • They’re 100 percent recyclable. So, when they finally come to the end of their lifecycle, they don’t take up landfill space.


Flexcon extends the uses and advantages of attached lid containers with its branded Temp-Pack™ Insulating Liner. The liner transforms an attached lid tote into a cooler.

Made of high density expanded polystyrene foam, the liner enables attached lid containers to handle temperature-sensitive products such as frozen and refrigerated food, biotechnology products and pharmaceuticals.

Flexcon offers attached lid containers in more than 90 sizes. To find the right containers for your applications, contact a Flexcon representative today.

Benefits of Corrugated Plastic Containers for ASRS Systems and Carousels

Automated storage and retrieval systems (ASRS) and carousels are designed to maximize effective use of space in manufacturing and distribution facilities with a high storage density, moving large volumes of parts and products in and out.

ASRS robot friendly totesThese systems’ economical use of space can be further maximized by choosing appropriately sized and designed plastic containers, totes and bins that fit the storage and retrieval system well and are the right size for the stored parts and products. This enables facilities to reduce wasted space and to increase effective storage capacity.

Plastic storage bins made by Flexcon Container, for instance, helped a manufacturer increase storage capacity in its automated storage and retrieval units by more than 19 percent, according to an article in Modern Materials Handling.

Flexcon corrugated plastic bins, totes and containers are designed to optimize use of available cube in carousel systems, reducing wasted space, common with other options, by 15 to 20 percent.

But size and fit aren’t the only important considerations when choosing containers for ASRS systems and carousels. Strength, deflection and impact resistance also are key attributes to consider. And for these and other reasons, corrugated plastic containers are excellent candidates for ASRS systems and carousels, both vertical and horizontal.

Why are corrugated plastic containers the right choice for ASRS systems and carousels?

Their benefits include:

  • While maximizing space usage, they minimize damage to materials and products during storage and handling as they are more durable and impact resistant than molded plastic containers. They stand up well under constant handling by robotic ASRS equipment. And unlike molded plastic, which can crack on strong impact, corrugated plastic containers resist tears and punctures.
  • They reduce costs as they last longer due to their durability.
  • For custom sized and designed containers required for specialized applications, corrugated plastic containers offer the advantage of requiring less development time than molded plastic containers–since they don’t require creation of a mold. Likewise, corrugated plastic containers require less production time than molded plastic containers. Production time for molded plastic can be nearly five times longer.
  • They’re lightweight, contributing to efficiency of ASRS systems. They help maximize pick rates.

In addition, corrugated plastic containers made by Flexcon Container feature:

  • Pitched drain holes to prevent collapse of a storage and retrieval system in the event a sprinkler is set off.
  • Ergonomic design for more efficient operation of carousel systems.
  • Design that prevents parts migration.
  • Capability of being partitioned to meet changing parts storage needs.

To learn more about the benefits of corrugated plastic containers, call Flexcon today at 908-871-7000. Our container experts are ready to help you choose the best solutions for ASRS and carousel systems. 

Plastic Pallet Sleeve Packs Are Packed Full of Advantages for Bulk Material Shipping and Storage

Pallet sleeve packs, made of corrugated plastic, offer many advantages for handling and shipping bulk materials—from being light weight and durable to their capability of being reused numerous times and saving money.

Pallet SleevesThese practical bulk material containers consist of a pallet base and a second pallet that fits on top, enabling stacking of pallet sleeve packs. Corrugated plastic sleeves act as walls, creating a sturdy shipping container that protects bulk materials in transit and storage. The sleeves snap into grooves in the pallet base and top to stay firmly in place while in use.

And when not in use, the pallet sleeves conveniently fold flat. This design feature, just one of many advantages of pallet sleeve packs, saves space in storage and return shipping.

Other advantages of pallet sleeve packs:

  • Reusable. Plastic pallet sleeve packs are a “green” solution because they are returnable and reusable. They can be reused dozens, even hundreds, of times. This reduces waste and disposal costs, which leads to the next advantage….
  • Economical. Because they can be reused, pallet sleeves reduce your total cost of ownership. You quickly recoup your initial investment because of their long-lasting nature. While wood pallets may last for a dozen uses or less, plastic pallet sleeve packs enable you to spread your investment over hundreds of uses.
  • Durable. They stand up to repeated use better than alternatives. They don’t splinter, crack or absorb moisture like wooden pallets.
  • Protective. Pallet sleeves reduce product and material damage as they offer optimal protection. They’re strong and durable.
  • Stable. Unlike wooden pallets, corrugated plastic pallet sleeve packs retain their size, shape and weight. They don’t warp or shrink. And they don’t absorb moisture and swell. Because they retain their shape they work well with automated material handling equipment.
  • Ergonomic. Plastic pallet sleeve packs are lightweight and easy to handle. They’re also easier on your workforce, resulting in fewer workplace injuries, because they don’t splinter or crack.
  • Hygienic. Corrugated plastic pallet sleeve packs can be easily cleaned and disinfected, so they are ideal for food and FDA approved applications, as well as pharmaceutical applications.
  • Customizable. Sleeve packs are attractive as they can be made in custom colors. The sleeves can be printed to identify your brand, which aids in return of pallet sleeve packs to your facility.
  • Nestable. Top and bottom pallets can be nested to save storage space. Further space savings can be realized, as the plastic sleeves fold flat between uses.

Pallet sleeve packs by Flexcon Corporation are available in stock pallet sizes of 48 x 45 and 48 x 40. In addition, other standard sizes are readily available, and Flexcon can manufacture custom size pallet sleeve packs and internal dunnage for your special applications.  We can even design custom pallet sleeve solutions that work with wooden pallets.

To learn more and take full advantage of pallet sleeve packs for your operations, contact a Flexcon sales representative today.

9 Benefits of Heavy Duty Plastic Bulk Containers

bulk boxesHeavy duty plastic bulk containers serve a wide range of industries for storage, picking, processing, assembly and distribution applications involving products and supplies of all shapes and sizes.

These containers prove to be flexible and durable solutions for light manufacturing, automotive, aerospace, appliance, paper, pharmaceutical, produce, bakery, poultry, apparel, electronics and other industries.

In this article we present 9 benefits of reusable plastic bulk containers:

  1. Exceptionally durable. Heavy duty plastic containers stand up to the abuse of multiple uses and return trips – typically hundreds – with minimal wear. In contrast, corrugated cardboard boxes deliver “one and done” service.
  2. Environmentally friendly. Because they can be used over and over, heavy duty plastic bulk bins, containers and totes preserve valuable resources and save landfill space. And they’re made of recyclable plastic, so they stay out of the waste stream even at the end of their service life.
  3. Moisture resistant. Unlike cardboard containers, plastic containers are weather-resistant, nonabsorbent and resist most chemicals. This contributes to longer life and provides superior protection of the materials and products the containers hold.
  4. Stackable. Due to their strength, heavy duty plastic bulk containers can be stacked six to eight high, as opposed to cardboard containers, which begin to buckle when stacked more than two or three boxes high. This optimizes use of warehouse space and maximizes transportation cube efficiency in over-the-road trucks.
  5. Greater carrying capacity. Many plastic bulk storage containers are rated to hold up to 2,500 pounds of materials or products, making them much more efficient than cardboard containers.
  6. Superior protection of contents. More than cardboard containers, plastic bulk containers protect their contents from damage in storage, handling and transit.
  7. Highly customizable. Heavy duty plastic bulk containers offer greater flexibility than cardboard for customization to specific application requirements. They can be designed to nest or collapse when not in use. For food, beverage and pharmaceutical applications they can be designed to meet FDA standards.  Other customizable features for plastic bulk containers include extended length, four-way fork entry, drop doors, a variety of sidewall configurations, casters, special hand-hold designs and RFID capability.
  8. Safe. Reusable plastic containers can be opened without box cutters and are free of sharp edges.
  9. Savings. Heavy duty plastic bulk containers deliver a quick return on investment and long-term cost savings, as they last longer, reduce product damage and loss, minimize landfill use and disposal costs, make better use of space, and reduce labor costs and increase productivity due to their superior efficiency.

bulk boxesWe realize we may have missed some of the benefits of plastic bulk containers in this list, so please share with us the advantages you have discovered in your experience of using heavy duty plastic bulk containers and totes. And contact a Flexcon sales representative today to help you take advantage of the benefits of our reusable plastic bulk containers for your applications.



Why are plastic dividers so important in material handling

Efficient and effective materials handling is essential for maintaining product quality and profit margins, making plastic dividers a necessity for quality assurance purposes. The impact of plastic dividers on operational efficiency and product quality cannot be understated, because protecting the integrity of production systems and inventory can make or break a business.

Plastic Divider Systems

Plastic dividers come in a number of different configurations, shapes and sizes, making it important to select the right divider system to meet your needs. For instance, Flexcon’s Perfect Divider System is available in 12 standard configurations, but you can customize your system at no extra charge. The dimensions of these dividers include lengths up to 160 inches with widths up to 48 inches and heights from 2-20 inches. Also, the dimensions of the dividers can be adjusted to make any size compartment that you need. These types of systems facilitate waste reduction and efficient cycle times, translating into higher levels of customer service and lower operating expenses.

Features and accessories included with Flexcon’s plastic dividers:

Standard and custom colors
Bottom pads
Foam pads
Bin cup inserts
Eight-layer paint job

Uses of Plastic Dividers

Some of the most popular applications of plastic dividers include in containers, bulk boxes and vertical lift modules. These applications help employees reduce part picking errors, while helping to facilitate the efficient and effective storage of parts inventory. The location of plastic dividers within shops or production facilities, along with the accessibility and organization of inventory, are critical factors in the overall efficiency of your operations.

Additional Benefits of Plastic Dividers

The benefits of plastic dividers impact multiple stakeholders inside and outside of your business. Employees will have an easier time finding, storing and utilizing materials within your business, which can make their jobs easier and boost their morale. Overall, they will be more efficient and effective at their jobs, making your business more profitable over the long run. Your customers also stand to benefit in terms of faster and more effective service, along higher quality products that meet or exceed their expectations.

In terms of waste reduction, plastic dividers eliminate excess materials or products not being utilized and the unnecessary movement of products or materials. Dividers can also reduce the amount of time employees wait for their next production component, allowing them to reallocate their time to value-added activities. Waste reduction alone is enough reason to implement plastic divider systems in to production facilities.

Without plastic dividers facilitating and enhancing the materials handling processes, businesses would face everything from waste and inefficiency to lost profits. The advantages of plastic dividers far outweigh their costs, which is they are used in shops and production faculties all over the world.