FedEx has rolled out a reusable packaging solution designed specifically for business-to-business operations, marking a shift in how goods are handled across its logistics network. Developed alongside circular logistics specialist Returnity, the initiative introduces containers engineered exclusively for FedEx, ensuring seamless integration into its existing infrastructure. The move positions reusable packaging as a practical alternative to traditional corrugated cardboard without triggering the additional handling fees typically associated with non-standard formats.
The newly introduced containers are built to align with operational efficiency requirements, featuring a “durable, collapsible” structure that is fully compatible with automated systems. Each unit is capable of supporting up to 50lb of goods and is designed for reuse across as many as 50 shipping cycles. By embedding reusable packaging into standard workflows, FedEx aims to streamline logistics processes while maintaining speed and reliability across its network.
Returnity CEO Mike Newman said: “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.” Unlike single-use packaging systems that depend on consumer returns, this model is structured for closed-loop environments, including fulfilment centres, store restocking, and service support operations. The design reduces dependency on end-user participation, enabling more controlled and consistent reuse cycles.
FedEx reports measurable operational and environmental gains from the system. According to the company, businesses adopting the solution could lower packaging costs by up to 30% per cycle while reducing carbon emissions by between 64% and 88% compared with single-use corrugated boxes. Participants have also observed faster unpacking and restocking, improved labour efficiency, better organisation in storage areas, and fewer cases of product damage. Currently available in the US, FedEx intends to expand availability to Australia and Europe in subsequent phases.
FedEx global customer experience senior vice-president Neil Gibson said: “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.
“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.”