Reusable corrugated plastic containers, totes, trays, and inserts from Flexcon are the most versatile on the market. Flexcon's Corrugated Plastic Container line has hundreds of sizes, dozens of styles and colors, and we also make this product in custom sizes with very little upcharge. Custom sizes, features, accessories, sheets and colors are available upon request. Ask about our signs and printing! Dealer inquiries welcome. Corrugated plastic containers provide:
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Flexcon’s corrugated plastic containers can last thousands of trips and picks, whereas a cardboard box might only last a few. The ROI is often achieved in fewer than 30 cycles, making it a highly economical choice for any closed-loop or reusable system.
Three differences decide it: Lifespan, Moisture & Strength, and Cost over time. Corrugated plastic lasts 7-10 years of repeated handling; cardboard is typically single- or few-use. Corrugated plastic is liquid-, oil-, and tear-resistant and holds shape in humid or wash-down environments; cardboard absorbs moisture and crushes. Though cardboard is cheaper per box upfront, reusable corrugated plastic spreads its cost across hundreds of trips, lowering cost-per-cycle and eliminating repurchasing. Flexcon containers add reinforced bottoms for low deflection under load and ultrasonically welded corners for a continuous high-strength bond.
Yes. Corrugated plastic is an extruded polypropylene sheet, making it completely waterproof and resistant to grease, oils, and many common industrial chemicals. It will not degrade or lose strength at all when wet.
Absolutely. This is a primary advantage of corrugated plastic. Flexcon can cut and weld the material to create a container of virtually any size or design with lower tooling costs, making it perfect for custom projects.
Flexcon uses sonic welding to construct our containers. This process creates a continuous, high-strength bond by melting the plastic together, resulting in a much stronger and more durable seam than metal staples, which can rust or pull through the material.
The smooth, flat surface of corrugated plastic is ideal for screen printing. Flexcon can print your logo, part numbers, or other information in sharp detail and vibrant colors that are much more durable than printing on cardboard.
Yes. The resin material used for Flexcon’s corrugated plastic can be made fire retardant, meeting the UL 94 HB flame class requirements for specific applications where fire safety is a primary concern.
Disposable packaging wins on upfront cost (a low per-box price) but is repurchased for every shipment. Reusable corrugated plastic containers carry a higher initial cost that is recovered over a 7-10 year service life across hundreds of trips, driving cost-per-cycle down. To compare for your operation, weigh: trips per year, container lifespan, and handling/cleaning costs against per-shipment disposable spend.
Yes, when engineered for it. Look for a reinforced, low-deflection bottom that resists bowing under load, welded corners, and standardized footprints that stack and index reliably. Flexcon builds containers in sizes from 2″ to 96″ with reinforced bottoms and ultrasonically welded construction, and supports barcode/RFID and ASRS/AutoStore automation. Specify your load weight and handling method and we engineer the wall, base, and footprint to match.
Connie, Sr. Material Handling Consultant
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