We redesigned the flower crates used for the (international) distribution of cut flowers between wholesalers. The use of large cardboard boxes generated too much waste, and some smart innovations have allowed us to make flower transport more sustainable.

Evolution in the sector

Flowers are very delicate and must be handled with care to ensure their freshness. The conditions in which they are transported, such as the right temperature, are crucial to their lifespan. In the 1980s, a plastic flower crate was already in use, but it quickly became obsolete and unsuitable for modern transport. Later, the sector returned to cardboard boxes, which led to significant waste. It was time to optimise the design of the plastic version again.

Transformation at multiple levels

The redesign of the flower crate brought several improvements, all aimed at optimising the logistics process. The old crate was too heavy and not flexible. As a result, it could only be fully stacked with the help of a metal handle, which generated a lot of noise in the production area. At Didak Injection, we injection-molded the new flower crate, as well as the new handle, which is now made of plastic. This offers a great advantage for recycling, as the crate is now made from a single material (monomaterial).

As initiators, Heemskerk Flowers Rijnsburg, Van der Plas Rijnsburg (Floral Trade Group), Celdomy Honselerdijk, and Argos Packaging Honselerdijk have found an ideal partner in Didak to bring their development into production.

In this new version, the metal handle has been replaced with a plastic version, improving recyclability. The crates can now be stacked up to 60%, allowing for economical transport at 50% load capacity. Additionally, the handle can now fold into the rim of the crate, so it no longer obstructs when the crates are nested empty.

To prevent deformation, the crate has been made sturdier, and we increased the capacity from 112 liters to 122 liters. By modifying the U-shaped edge into a straight edge and using plastic with a foaming agent, we reduced the height while maintaining strength. The result: a solid business case, as truck loads (and therefore costs) remained equivalent to those of cardboard boxes, while benefiting from the advantages of a sustainable crate.

A third optimisation involved adding leaf-shaped notches on the sides of the crate, allowing rubber bands to be easily attached to hold the flowers in place during transport. Cutouts were made on the upper rim for PP plastic straps. A printed cardboard sheet is placed over the flowers and securely fastened with 1 to 3 plastic straps.

Additionally, we designed the labeling areas with embossing to make stickers easier to remove and integrated RFID tags into the wider top rim for better automation. The bottom of the crate is equipped with a rim and a ribbed pattern for better grip on conveyor belts – an important improvement for automated processes.

Optimal water drainage and user-friendliness

At Didak Injection, we ensure our products meet all our clients' needs. That’s why, in addition to logistical optimisations, we also focused on user-friendliness and modernisation. The bottom of the crate was redesigned with a concave shape that directs water to drainage holes. This keeps the flowers dry, as the buds rest on slightly raised surfaces. This not only improves water drainage but also makes the crate easier to clean due to rounded corners.

The shell handle provides a comfortable, integrated grip for optimal use. An important advantage of this handle is that the flower heads are not touched by employees, offering additional protection compared to the open handles of cardboard boxes.

RFID labels for tracking

The crate is also equipped with RFID labels offering four different tracking methods:

• Human readable GS1-GRAI nummer.
• 2D barcode.
• QR matrix.
• RFID number.

All these methods generate the same number in computer logs, regardless of the technology used. This makes the crate easily scannable in any situation within the logistics flow.

Optimise or design your own product 

After reading this article, do you have a product that needs optimisation? Or are you interested in developing an entirely new product? Our team of experts is ready to explore the possibilities with you. Contact us today at info@didak.eu.