FedEx, Returnity launch reusable box solution for B2B shippers

FedEx has launched a new reusable packaging system for business-to-business (B2B) shippers in collaboration with Returnity. The cost-effective solution features a FedEx-specific box design and allows B2B customers to switch from corrugated to reusable boxes in their supply chains without incurring the handling fees usually associated with alternative packaging formats.

The reusable box was developed with Returnity, a provider specialising in circular logistics. According to the companies, the system aims to help FedEx B2B customers adopt reusable packaging more easily within their existing shipping operations.

Neil Gibson, Senior Vice President, Global Customer Experience at FedEx, said the collaboration has created the first scalable reusable box solution for B2B customers, particularly for soft-goods shippers. By combining Returnity’s packaging with the FedEx network, the company said retailers can achieve cost savings while reducing environmental impact without affecting speed or reliability.

Reusable packaging has existed for years, but integrating it into parcel networks has often been difficult due to cost, operational complexity and compatibility with existing logistics systems. The new box was designed to address these challenges by providing a durable, collapsible and automation-friendly container that works within the current FedEx infrastructure.

The system is designed for closed-loop environments where packaging returns are predictable, such as in-house fulfilment centres, store restocking operations and field service support. Each box is engineered for up to 50 shipment cycles and can carry shipments weighing up to 50 pounds. FedEx said the packaging format could reduce packaging costs by up to 30 percent per cycle and lower carbon emissions by 64–88 percent compared with single-use corrugated packaging under typical conditions.

The reusable packaging system has been piloted with several FedEx B2B shippers across North America. In the pilot programme, shippers reported faster unpacking and restocking, higher labour efficiency, improved backroom organisation and lower product damage rates.

The solution is currently available to FedEx customers in the United States, and the company plans to expand it internationally to Australia and Europe in the near future.