How Custom Industrial Tote Boxes and Dunnage Improve Parts Handling in Manufacturing

A Tote Box Is Part of the Manufacturing Process

Industrial tote boxes are easy to underestimate.

They may look like simple containers, but inside a manufacturing plant they often move repeatedly between machining, inspection, assembly, temporary storage and line-side work areas.

A tote may be loaded dozens of times, transferred between workstations, stacked, emptied and returned to the previous process.

That means selecting a custom industrial tote box is not only about choosing an external length, width and height.

For many components, the real question is what happens inside the tote.

If parts can move freely, touch each other, arrive in the wrong orientation or need to be reorganized before the next operation, the container is not fully supporting the production process.

This is where custom dunnage becomes important.

Why Internal Dunnage Changes the Way Parts Are Handled

The tote shown here uses a fitted internal locating structure with individual positions for the components.

Instead of placing parts loose inside the container, each part has a defined location.

This type of arrangement can improve several practical aspects of internal logistics.

Parts are less likely to move during handling. Operators can see more quickly whether a location is full or empty. Components can arrive at the next workstation in a more consistent arrangement. The same tote can also be reused without rebuilding the internal packing pattern every time.

For repetitive production, these details matter.

Current returnable packaging suppliers increasingly describe custom dunnage and tote systems as part of manufacturing material flow rather than simply protective packaging. Dunnage Engineering, for example, positions custom trays and totes for shipping, handling and processing, including in-process handling and automation-related applications.

Part Protection Does Not Always Require More Disposable Packaging

When a component needs protection, the first solution is often more foam, wrapping or disposable packing material.

That approach may be suitable for some shipping applications, but internal factory logistics works differently.

A tote used for work-in-process material handling may circulate repeatedly between operations. Repacking components every time they move adds labor and material.

A fitted dunnage insert takes another approach.

Instead of surrounding the product with more packaging, it controls where the part sits and how much it can move.

For some components, preventing part-to-part contact is more useful than adding another layer of disposable material.

This is one reason reusable packaging systems are increasingly used for in-plant material flow and closed-loop supply chains. Current industry suppliers also emphasize reusable plastic containers, dunnage and returnable packaging for repeated handling, storage and production workflows.

WIP Handling Works Better When the Loading Pattern Is Repeatable

Work in progress rarely stays in one place.

A component may move from machining to inspection, then to assembly, temporary storage or another production operation.

If every operator loads the same part differently, internal logistics becomes harder to control.

A WIP material handling tote can help standardize this movement.

The outer container provides a consistent handling unit. The internal dunnage defines how the parts are positioned.

This can reduce situations where components are mixed, stacked directly on top of each other, placed in different orientations or difficult to count at a glance.

The operator does not need to decide how to arrange the contents every time.

The tote already defines the loading pattern.

Custom Dunnage Should Be Designed Around the Part

A common mistake is to choose a standard insert first and then try to fit the component into it.

For customized manufacturing applications, the more practical approach is usually the opposite.

Start with the part.

Its geometry, weight, contact surfaces, fragile areas, loading orientation and handling method should influence the internal design.

The required quantity per tote also matters.

If the insert is too dense, operators may struggle to remove components. If the cavities are too far apart, usable space may be wasted. If the full tote becomes too heavy, manual handling may become uncomfortable.

For this reason, a custom parts handling container should balance protection, capacity and operator access rather than simply maximizing the number of parts.

Orientation Can Matter as Much as Protection

Not every component needs a fixed orientation.

But some production processes benefit when every part arrives in the same position.

A specific surface may need to remain protected. An operator may need to lift the component from one side. A fixture may expect the part to be presented in a particular direction.

In these cases, internal dunnage does more than stop movement.

It helps create a repeatable relationship between the component and the next manufacturing step.

That can be useful in manual production, inspection and assembly environments.

It can also become more important if the factory later introduces automated handling.

The Outer Tote Still Has to Match the Material Flow

Good internal dunnage cannot compensate for a poorly chosen outer container.

The tote still has to work with the surrounding factory environment.

External dimensions may affect compatibility with carts, shelving, racks, conveyors and storage locations.

The base geometry influences how the tote sits on work surfaces and handling equipment.

Stacking surfaces matter if multiple totes are stored vertically.

Handles and access areas affect manual handling.

For this reason, developing a custom industrial plastic tote should normally begin with the complete material flow rather than the part drawing alone.

The tote and the dunnage need to work as one system.

Front, Side and Inside Views Reveal Different Design Requirements

One photograph is rarely enough to evaluate a custom tote.

The front view shows the overall profile and lower structural geometry.

The side view helps explain the base and side-wall design.

The inside view shows the most application-specific feature: how the parts are actually located.

Two containers may look almost identical from the outside while using completely different internal dunnage.

That is often the main difference between a general storage bin and a custom industrial parts handling tote.

Reusable Totes Support Closed-Loop Internal Logistics

Many manufacturing plants operate with a simple closed-loop flow.

A tote moves from one process to another, the parts are removed, and the empty container returns to the previous area to be filled again.

In this type of application, repeatability matters more than appearance.

The same container dimensions, the same part positions and the same loading method can be used cycle after cycle.

This is where reusable parts totes for manufacturing become especially useful.

Current returnable packaging suppliers increasingly describe these systems in terms of reusable containers, in-plant material flow and closed-loop supply chains rather than one-way packaging.

Capacity Is Not Simply the Maximum Number of Parts

It is natural to want as many components as possible in each tote.

Higher capacity may reduce the number of transport cycles.

However, maximum density is not always the best solution.

If components are packed too closely, operators may have difficulty removing them.

If the cavities leave too little clearance, handling interference may increase.

A heavier loaded tote can also make manual transfer more difficult.

The useful capacity is therefore the number of parts that can be protected, transported and handled efficiently.

This is particularly important when the tote circulates repeatedly during daily production.

What About Conveyors, ASRS and Automated Handling?

Automation introduces another level of requirements.

When a tote is handled manually, small dimensional differences may not cause an immediate problem.

When the same container needs to move through conveyors, automated storage, shuttle systems or robotic handling, consistency becomes much more important.

Current automated storage tote suppliers emphasize features such as dimensional stability, base geometry, repeatable movement, conveyor compatibility and system-specific customization. ORBIS, BITO and other suppliers now position reusable totes specifically around automated storage and material handling environments.

Recent ASRS tote guidance also stresses that standard totes may not be sufficient when automation interfaces, payload protection or traceability requirements become more demanding.

This does not mean every custom industrial tote should be described as an ASRS tote.

That would be inaccurate unless it has actually been designed and validated for the equipment.

But if future automation is part of the factory plan, it is worth considering those requirements before the tote design is finalized.

When Does a Custom Tote Make Sense?

A standard plastic tote is often the right choice for general storage.

Customization becomes more valuable when the parts or process create requirements that a generic container cannot solve well.

Examples include irregular component geometry, sensitive surfaces, fixed quantities, orientation requirements, repeated WIP transfer or integration with dedicated carts and handling equipment.

In these applications, the tote becomes part of the manufacturing system rather than just packaging.

Start With the Real Material Flow

A useful tote project should not begin with one question:

“What box sizes are available?”

A better starting point is the production process.

Where does the part come from?

Where does it go next?

How many pieces move together?

How does the operator load and unload the tote?

Does the component need a fixed orientation?

Will the empty tote return to the previous workstation?

Will the container later interact with racks, carts, conveyors or automation?

Once these questions are clear, the tote dimensions and internal dunnage can be developed around the real application.

That is the value of a custom industrial tote box with dunnage: not simply producing a different-shaped container, but creating a more controlled, repeatable and practical method for moving parts through manufacturing.

FAQ

What is a custom industrial tote box?

A custom industrial tote box is a reusable container designed around specific manufacturing, storage or parts-handling requirements. Dimensions, structure and internal dunnage can be adapted to the component and material flow.

What is custom dunnage?

Custom dunnage is an internal locating or protective structure designed around the geometry of a specific part. It can separate components, restrict movement, maintain orientation and make loading positions easier to identify.

Why use individual part locations inside a tote?

Individual locations can reduce part-to-part contact, make quantities easier to check and create a more consistent loading pattern between production processes.

Can tote boxes be used for WIP material handling?

Yes. Reusable totes are commonly used for WIP movement between machining, inspection, assembly, storage and other manufacturing steps.

Can a custom tote be used with automated handling?

It can be designed for automated handling, but compatibility should be confirmed separately. Dimensions, tolerances, base geometry, payload and equipment interfaces all need to be considered.

What information is needed for a custom tote project?

Useful information includes component dimensions, weight, quantity per tote, sensitive surfaces, loading orientation, handling method, outer-size limitations and the way the tote will move through the factory.