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DS Smith designs plastic reusable tote for Zara

Published 12 February 2018

Zara has selected DS Smith Plastics, Injection Moulded Products to design a tote to meet all their expectations.

ZARA, a clothing company, needed a reusable and nestable tote to use in the fully automated distribution centre.

ZARA had recently installed fully automated systems in their distribution centre which included ‘goods-to-person picking equipment’. Goods-to-person is a modern method of order fulfilment where the product is moved directly to the operator who can then pick the product to be fulfilled.

This type of system increases the pick efficiency which, in turn, speeds up the pick process. However, the previously used totes did not provide stable stacking which were now required by their new automated handling systems.

This system is based on the ‘ZARA formula’, a highly responsive supply chain that ships their automated picking system.

To suit this state-of-the art system, DS Smith Plastics designed a reusable plastic tote to comply with all the requirements. The tote has a non-standardized dimension of 650x450 mm (approx.) to be used with the fully automated picking system.

The sustainable material, from which the new reusable plastic totes are manufactured, is hygienic and easy to clean.

Due to their low weight and ergonomic handles the boxes are user-friendly. The reusable totes are stackable, and when they are empty and turned 180° horizontally, they become nestable which saves 70% of warehouse space.  

By replacing single-use storage with reusable totes, ZARA was able to reduce their packaging waste to a minimum. With this investment in reusable plastics packaging, ZARA is making an important contribution to the environment. Moreover, DS Smith Plastics, Injection Moulded Products totes have a long life span and are 100% recyclable at the end of their useful life.

Zara is a Spanish clothing company that is part of the quoted fashion giant Inditex. Zara's products are supplied based on consumer trends. Its highly responsive supply chain ships new products to stores twice a week.

After products are designed, they take ten to fifteen days to reach the stores. All of the clothing is processed through the distribution center in Spain. The fashion group also owns brands such as Massimo Dutti, Pull & Bear and Bershka.



Source: Company Press Release