Engineering Better Reusable Bulk Containers for the Automotive Industry

April 30, 2026

ORBIS BulkPak HDMP collapsible containers. (ORBIS)

Reusable bulk containers protect parts and components as they move from suppliers to assembly operations. These containers are especially common in the automotive industry, where they help streamline material flow for OEMs and Tier 1s. Given this widespread use, it can be beneficial to learn about bulk container design.

A key place to start is understanding the engineering considerations behind the container design, especially when considering their use in the automotive industry.

Starting with the part

The priority should be to plan for every part, specifically when engaging with OEM customers during a new vehicle launch. The priorities are part protection, shipping optimization and line-side efficiency. Designers should look at part size, type and shape to maximize the number of parts per bin.

For example, a wiring harness can be very long and does not need much dunnage or protection, so it could be bulk loaded in a large container. However, when packaging Class A parts, including mirrors, headlamps or decorative trim, we want to ensure we are protecting them with custom dunnage while increasing pack density.

Determining the right footprint

When designing a bulk container and determining how it can be packed out most efficiently, our engineering team also factors in different container sizes and footprints to optimize the space in a standard 53-ft (16 m) trailer. The goal is to maximize the number of parts per bin and bins per truck to help customers save logistics costs and avoid “shipping air.” For return trips to the supplier for part replenishment, empty bins collapse to save space.

When it comes to the automotive industry, 48 in x 45 in (122 cm x 114 cm) bulk containers are the standard for a large majority of parts and products, with consistent and predictable capacities. Extended footprints are used for larger, bulkier parts, including a variety of standard footprints, from 32 in x 30 in (81 cm x 76 cm) to 78 in (198 cm) x 48 in (122 cm) and in heights from 18 to 50 inches (46 cm to 127 cm). Bulk containers can also be custom-designed and fabricated for specific application requirements.

Taking ergonomics into account

Understanding how the workforce interacts with parts on the assembly line also plays a role in container design. We consider ergonomics early in the process, looking at the container size, height, number of access doors, door width and door configuration. We always try to maximize door size, so it is easy for a worker to reach in for parts at the line.

One OEM had a 48 in x 45 in x 34 in (121 x 114 x 86 cm) container and found it was more ergonomically friendly to have doors on all four sides to access parts. Additionally, well-designed containers can have easy-to-grab sidewalls and latches, so they are easy to assemble and collapse.

Accounting for the load rating

When designing bulk containers, engineers should seek to understand the application requirements and how the bin is used, racked, stacked, and shipped. For example, designers at ORBIS use Automotive Industry Action Group (AIAG) standards to design for load capacity. Generally, bulk container load ratings range from 1,000 to 2,500 lbs (450 to 1,150 kg) per container.

Selecting the right bulk packaging style

Collapsible bulk containers are available in a range of styles and capacities. Container selection depends largely on the load weight and part size. Sleeve pack solutions, comprised of a pallet, sleeve and top cap, are ideal for lighter-weight loads like automotive seat foam. Rigid structural foam containers are typically used for medium to heavy applications up to 2,500 lbs. (1134 kg). For loads above 2,500 lbs., custom-fabricated metal racks are recommended.

OEMs also have different mindsets about how they want to package and ship parts. OEMs determine whether to use hand-held totes or bulk containers based on their part packaging strategy and the specific demands of their production flow and lineside assembly processes.

Material matters

Reusable bulk containers play an important role in helping OEMs and tier suppliers meet sustainability goals. They support the circular economy by traveling hundreds of trips over their lifetime and when they reach end-of-life, containers are recovered and reprocessed into new products using recycled resin. More OEMs are asking for packaging made from post-consumer recycled (PCR) content and suppliers should work with them to determine the right PCR levels, while maintaining container durability and performance.

Designing for automated systems and equipment

According to Cyngn, more than 45% of manufacturing leaders cite automation as their top investment priority in 2026. Product engineers should design with automation considerations in mind to ensure that bulk containers interface seamlessly with new automated equipment. This might include changing or modifying standard bulk containers or potentially building a new container for a new automated system. Bins can be molded for dimensional consistency to ensure repeatable performance within automation, with smooth surfaces for tags and labels that can be easily read by vision systems.

Establishing checkpoints along the way

As OEMs launch new vehicles and suppliers design new parts, planning new packaging is often required. Container suppliers should work closely with customers to design the right solution and plan a pilot program to ensure a successful launch. Companies that can create prototype bins and dunnage solutions for on-site customer approval can ensure that part fit, protection and density all meet expectations. This feedback loop is crucial to be responsive to customers.

Ultimately, engineering a standard bulk container for the automotive supply chain involves a balance of part protection, lineside requirements, and logistic demands while supporting modern manufacturing environments that are increasingly relying on automation. As automotive requirements continue to evolve, thoughtful engineering will help ensure reliability, efficiency and long-term value across the supply chain.

Chad Mosley, below, is senior product manager for the ORBIS Corporation and wrote this article for SAE Media.