A major retail chain has adopted The Last Box, Returnity’s reusable packaging box solution, in a move hoped to streamline backroom operations and cut down on single-use waste.
According to Returnity, retail backrooms are currently being used for processes like e-commerce returns, ship-from-store, same-day pickup, and managing seasonal surges – but their physical layout and tools are not always compatible.
“Retail backrooms weren’t built to be fulfilment centres, but that’s what they’ve become,” explained Returnity CEO Mike Newman. “Teams are managing more products with less space and under tighter timelines.”
Returnity adds that solutions like single-use cardboard were ‘never intended for modern retail’.
The Last Box serves as an alternative format, designed to withstand multiple stages of operations through distribution centres and stores – including inbound deliveries, internal transfers, order staging, and restocking.
First launched in April 2023, The Last Box originally sought to replace almost four million cardboard boxes for shipping and delivery in retailers’ internal operations in its first year. Each container was set to eliminate 50 cardboard boxes and 300 feet of packing tape.
By maintaining its durability through repeated uses, The Last Box is now expected to reduce packaging waste in thousands of high-volume locations. The major retailer has reportedly deployed over 100,000 units within months, with associate demand and evident impact said to drive expansion across high-volume fulfilment workflows.
Various retailers piloting the system have also said that the solution has improved inventory handling, decreased product loss and damage, and saved time by removing excess cardboard.
Fulfilment locations supporting delivery through personal-vehicle networks are thought to benefit the most. Due to their limited space and fast turnarounds, even minor efficiencies can cause losses or delays.
“Some stores were staging orders in hallways or converting small offices just to keep up,” Newman continued. “This isn’t just a packaging issue. It’s a systems issue, and better tools are helping retailers restore flow and efficiency.”
Returnity says that ‘many’ stores are now using The Last Box in their daily operations, whether to transport and stage internal parcels from distribution centres, streamline pick-and-pack for kerbside or local delivery, or package outbound transfers and returns.
The Last Box is expected to help retailers introduce and operate circular systems and hybrid fulfilment models, all while reducing reliance on less robust, single-use packaging solutions.
A similar development took the spotlight at the Sustainable Packaging Summit 2025, Klingenberg’s reusable, tape-free e-commerce box, Nomadbox, winning the Pre-Commercialized Driving the Circular Economy award. Its patented Monozip closure is believed to improve stability, flexibility and user friendliness, while the format as a whole is thought to facilitate both reuse and end-of-life recycling.
In other news, Evri recently joined forces with Vinted to provide free reusable packaging at various Evri ParcelShop locations, helping users cut down on single-use packaging waste while reselling second-hand products.
If you liked this story, you might also enjoy:
The ultimate guide to the Packaging and Packaging Waste Regulation in 2025
How are the top brands progressing on packaging sustainability?
Everything you need to know about global packaging sustainability regulation in 2025
The key to increasing the use of reusable packaging in supermarkets
No comments yet