First-to-market system designed to reduce costs and streamline store operations
FedEx Corp has announced the launch of a new reusable packaging system for B2B shippers. This cost-effective solution was developed in collaboration with Returnity, a reusable packaging provider specializing in circular logistics, and features a FedEx-specific box design. Together, FedEx and Returnity have enabled FedEx B2B customers to easily make the switch from corrugated to reusable boxes within their supply chain without incurring the handling fees typically applied to alternative packaging formats.
“In collaboration with Returnity, we have created the first scalable, reusable box solution for B2B customers, which is especially useful for our soft-goods shippers,” said Neil Gibson, senior vice president, global customer experience, FedEx. “By pairing Returnity’s durable, easy-to-integrate packaging with our global network, we’re helping retailers unlock meaningful cost savings while reducing environmental impact, all without sacrificing speed or reliability. This new solution supports our vision to make supply chains smarter for everyone.”
“FedEx made reuse make sense by building the business case, doing the work, and creating a model for how circular logistics can succeed at scale,” said Mike Newman, CEO of Returnity.
Optimizing the B2B Supply Chain Experience with Reusable Packaging
While reusable packaging isn’t new, its integration into traditional parcel networks has long been hindered by cost, complexity, and fit within existing logistics systems. The box was designed to address these barriers by providing a durable, collapsible, and automation-friendly container that works within the current FedEx infrastructure.
Unlike consumer packaging, which relies on unpredictable customer return paths, this solution is designed for closed-loop environments. It is well-suited for in-house fulfillment centers, store restocking, or field service support, where returns and reuse are controlled and predictable. Each box is engineered for up to 50 shipment cycles and can ship up to 50 pounds worth of goods. The result is a smarter packaging format that cuts packaging spend by up to 30% per cycle and could reduce carbon emissions by 64%-88% compared to single-use corrugated packaging under typical conditions, assuming a non-return rate of 40% or less.
Enabling Reusable Packaging at Scale
The system has been successfully piloted with multiple FedEx B2B shippers throughout North America, validating its performance across real-world retail and distribution workflows, including fulfillment-to-store replenishment, internal transfers, and reverse logistics.
In the pilot program, shippers reported faster unpacking and restocking, increased labor efficiency, improved backroom organization, and lower product damage rates.
FedEx customers in the U.S. can contact their FedEx sales representative directly to learn more about this new reusable box solution. While the packaging is currently available in the U.S., the company has plans to expand internationally in Australia and Europe in the near future. Learn more about the FedEx approach to sustainability and the company’s goal of carbon-neutral global operations by 2040 here
