The contents of this article is everything you need to know about plastic totes and their use.
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Plastic totes are robust, moveable containers crafted from strong materials, perfect for both industrial and home storage purposes. They come in numerous sizes, colors, and styles and serve various functions. Common types of plastic totes include bulk, insulated, collapsible, and handheld varieties, each designed for certain storage needs. These totes are specially constructed to manage varying tasks due to their distinctive designs and resilient materials.
The concept of plastic totes varies among industries. Generally, a tote signifies a container used to transport large or unusually shaped objects. In agriculture, they carry harvested crops, while in the automotive industry, they store and move parts to assembly units. Within homes, they aid in organizing areas such as closets and garages. Their adaptability makes them an asset for a vast array of storage, transportation, and organizational purposes.
The selection of plastic for tote production is influenced by factors like size, strength, and purpose. Commonly used plastics include polyethylene (PE), polypropylene (PP), polyvinyl chloride (PVC), acrylates, and acrylics. The thickness of the tote’s walls impacts its usability, with industrial-grade totes necessitating thicker, more durable walls compared to the lighter, less rugged household variants.
Although a storage tote may appear straightforward, selecting the right one for a specific use can involve more factors than expected. Totes generally have a rectangular or square shape, but variations in plastic materials, dimensions, wall strength, and lid designs mean they can be categorized into several distinct types.
Understanding how various totes store and safeguard their contents is essential, as selecting the correct one can enhance storage efficiency and make it easier to retrieve items. While totes are initially classified into four main categories, each category has additional factors that further define its purpose and application.
When choosing storage containers, it's important to factor in the amount of space they occupy due to their dimensions and design. A collapsible tote offers two modes. When fully extended, its sides and lid secure firmly for ease of stacking, loading, and moving. Based on the type, its solid walls help contain smaller items securely inside.
When a collapsible tote is folded, it transforms into a slim, flat rectangle that can easily be stored on a shelf. This compact form allows several collapsed totes to be neatly packed into a vehicle for convenience. This space-saving feature is a key reason why collapsible totes are so popular. Unlike bulkier or insulated totes, collapsible versions can be set aside when not in use, occupying minimal space.
Collapsible totes are available in various styles, all featuring the same collapsible functionality but differing in design. The primary options include totes with or without lids, as well as collapsible crates that resemble totes but lack solid sides.
Insulated plastic totes often look much like standard totes, whether collapsible or not. However, they stand out due to their construction, featuring thick, double-walled sides with an insulating core. Typically, these totes are used to transport food items that need to be kept cold.
Insulated totes, designed for the food industry, must comply with Food and Drug Administration (FDA) regulations. These standards require the use of non-toxic, high-density plastics that are hygienic and resistant to bacterial growth. Additionally, some insulated totes come equipped with drain-off lids to facilitate water removal after cleaning.
Insulated totes, used across various industries, are known for their durability and robust construction, which allows them to endure the harsh conditions of freezers and refrigerators. Larger models often feature slots for forklift handling, enhancing their strength and overall durability.
Bulk plastic totes are significantly larger than other types and are built to handle substantial loads. They feature thick, heavy-duty walls and bottoms crafted from robust plastics designed to endure heavy weights and rigorous shipping conditions. Due to their size, bulk plastic totes are equipped with features for forklift use, as they are too large to be lifted manually.
The 4 series or combo series bulk plastic totes feature a replaceable pallet attached to the bottom, which can be bolted or welded to enhance the tote's lifespan. Their sturdy design and durability make them a popular choice across various industries. Made from molded plastic, these totes are FDA and USDA approved. The four-way forklift entry points facilitate easy storage and movement of 4 series bulk plastic totes.
The 2 series bulk plastic tote is designed with two forklift entry channels integrated into its molded structure, enhancing both durability and functionality. Like the 4 series, these totes are also FDA and USDA approved, making them appropriate for food transport.
Bulk plastic totes also come in collapsible versions, which simplify their storage and handling. Similar to smaller collapsible totes, these larger models feature sides and lids that fold inward. However, bulk collapsible totes fold down onto their pallet-style base, allowing multiple totes to be stacked and lifted by a forklift for easy placement on storage racks. This design is particularly useful for long-distance truckers who need to deliver goods, return the totes, and pick up new loads.
Among the different types of totes, handheld models are the most popular and versatile, used both at home and in industrial settings. Traditionally, people have relied on sturdy cardboard boxes to store valuable items. However, these boxes often degrade over time due to moisture and temperature fluctuations.
Advancements in plastic technology have allowed manufacturers to create small totes that are more durable, reusable, and lighter than traditional cardboard boxes. These handheld totes are perfect for secure stacking and organizing industrial parts and components. In retail, they are well-suited for storing items such as baby clothing, jewelry, and accessories. With a variety of sizes available, handheld totes can be chosen to best fit the specific needs of different types of merchandise.
Handheld totes, like all totes, differ based on the types of plastics used and the thickness of their walls. For commercial and industrial purposes, these totes are constructed with robust, thick walls made from high-density, durable plastics. On the other hand, residential handheld totes come in a variety of sizes, making them suitable for storing items like sewing supplies, clothing, bedding, tools, and various other household goods.
Handheld totes are valued for their durability and longevity, making them ideal for both residential and industrial applications. Unlike standard cardboard boxes, which typically last between 1 to 5 years under favorable conditions, a plastic handheld tote can remain in good condition for 5 to 10 years or more, showing little to no signs of wear.
Handheld totes are available in various styles, including collapsible, with attached lids, with unattached lids, and featuring either smooth or grooved interiors. All types are designed to be stackable; solid handheld totes are typically nested, where one tote fits inside another, while collapsible models fold down similarly to larger collapsible totes for compact storage.
The department of transportation has certain specifications regarding the use of totes that are used for the transport of hazardous materials. Part of the qualifications for DOT totes includes a sealable lid and fasteners to keep the tote securely closed. Additionally, DOT totes have flat smooth interiors with rounded corners to prevent the collection of materials in the corners of the tote.
DOT-classified totes are renowned for their durability, crafted from high-density plastics designed to withstand the rigors of frequent travel and usage. These totes are easily cleanable, come in a distinctive yellow color, and are designed to stack securely without shifting. The primary focus of DOT regulations is on the safe transportation of hazardous materials. These totes are marked with DOT warning labels on their yellow surfaces to clearly identify the contents and associated risks.
DOT regulations often pertain to bulk plastic totes used for shipping, which are large and designed with forklift channels or sit on pallets. Some DOT totes feature four legs instead of channels or pallets to facilitate easy forklift handling. There are nine classes of DOT hazardous materials, and certain classes can be transported using DOT-approved totes.
Most totes are designed to nest, meaning they fit into one another to save space. This nesting capability makes them among the most popular types of totes. In the tote industry, the term "nesting tote" is frequently used to describe containers that can be stacked inside each other. Like collapsible totes, nestable totes are valued for their efficient storage when not in use. However, IBC totes are an exception due to their protective cages, which prevent nesting.
Nesting totes have countless applications, including those approved by the Transportation Security Administration (TSA) for use in airports. These industrial-grade nesting totes, such as TSA-approved models, are constructed from high-density plastics that provide durability, longevity, and resistance to tough conditions. They serve as a robust and resilient alternative to traditional cardboard boxes.
A unique functionality for nesting totes is as conveyor totes that are used by distribution centers, fulfillment centers, and industrial manufacturing. These totes are used to move products and material to different locations such as shipping and receiving, order pickup, and production lines. Conveyor plastic nesting totes are secured on a conveyor belt and designed to move smoothly and easily with the belt due to their non-slip grip bottoms.
Stackable totes share similarities with nesting totes, as they can be easily arranged for efficient storage. However, stackable totes are distinguished by internal load-bearing ribs that allow one tote to rest securely on top of another without requiring a lid. This design enables the totes to be stored without being sealed or closed, and prevents them from nesting into each other.
Some totes are designed to be both stackable and nestable. These totes feature ribs that allow them to nest inside one another or be stacked. To stack a tote that is currently nested, you need to remove it from the nesting position, rotate it 180°, and align the ribs of the upper tote with those of the lower one. Once the ribs are properly aligned for load-bearing, you can place the upper tote on top of the lower one.
Stackable totes are highly valued for their space efficiency, ease of access, visibility, and versatility, making them ideal for use in manufacturing, schools, homes, and warehousing and distribution. Among their many benefits, the ease of access stands out, as stackable totes allow for quick retrieval of items, whether you're organizing a shipment or storing items in a hurry.
IBC totes are specialized containers featuring a distinctive design that varies among models. Some have a robust wire framework with plastic panels, while others are designed for mixing purposes. These totes are ideal for transporting bulk liquids, granular substances, powders, and dry chemicals. Typically rectangular or square, IBC totes are unique in their inclusion of nozzles or valves for easy dispensing. Mixing models come with a valve for dispensing and a top opening to accommodate a folding blade mixer. Valves are positioned on the sides or the top of the totes, with an option for attaching hoses for fluid transfer. To ensure worker safety and environmental protection, these valves are secured with pressure clamps to prevent any leaks or spills.
The IBC tote concept was introduced in 1992, designed to offer a high-capacity, rigid, and durable solution that could be portable and, in some cases, collapsible. This innovation aimed to provide a more practical alternative to 200-liter (53-gallon) drums for the transportation, storage, and handling of powders and liquids. The traditional drums posed challenges due to their top-only access, making handling and emptying cumbersome. While the patent for IBC totes was filed in 1992, their origins trace back to 1984 with the introduction of fluid bags. These early models were well-suited for liquids and powders but lacked the rigid structure of the later IBC totes.
IBC totes are built to be reusable, stackable, and robust, making them suitable for handling various liquids and solids. Some models feature frames that remain upright during use but can be folded for compact storage. The versatility and efficiency of IBC totes have led to their widespread adoption as a superior alternative to conventional drums.
IBC totes come with a distinctive gauge that enables users to monitor the volume of the tote's contents. Models equipped with a steel cage are specifically designed to shield the tote from damage caused by forklifts, pallet jacks, and other solid objects. This cage not only safeguards the tote's exterior but also ensures stability and balance during transport and storage. The bases of these totes, which support the plastic container and cage, can be made from various materials and may be either fixed or removable based on the design. IBC totes are favored for their reliable valves, nozzles, drains, and spouts, which facilitate easy access to the contents and adhere to federal regulations and certification standards.
Metal cage IBC totes are DOT certified for the secure storage of chemicals, as the steel cage helps contain potentially unstable materials and prevent explosions. Additionally, these totes are equipped with vents to release vapors if the internal temperature of the contents becomes dangerously high.
IBC totes are highly valued for their versatility and adaptability, making them a top choice for shipping containers. Their wide range of types allows them to meet the specific requirements of various industries and applications. The International Organization for Standardization (ISO) has established criteria for IBC totes, specifying that they must have a capacity of 3 cubic meters (3000 liters) or 793 gallons. According to ISO standards, these totes should be mechanically handled, withstand the rigors of shipping and transport, and be suitable for the safe transport of liquids, solids, or pastes.
IBC totes come in a range of capacities from 110 gallons to 550 gallons and measure 45 inches in length and width, matching the dimensions of standard pallets. The height of an IBC tote varies depending on its capacity. Flexible IBC totes, constructed from plastics, are designed to collapse when empty for convenient storage. In contrast, heavy-duty IBC totes, made from robust plastics, feature rigid sides and can also be collapsed. All types of plastic IBC totes are user-friendly, versatile, and highly durable, capable of transporting a diverse array of products and materials.
IBC tote bins feature a metal framework that encases a plastic container. They are mounted on a fixed pallet base, allowing for easy access by forklifts and pallet jacks. The cage is constructed from reinforced steel, providing robust protection for the inner tank, which is made from durable and resilient plastics. This design makes IBC tote bins exceptionally sturdy, long-lasting, and well-suited for storing hazardous materials.
IBC tote bins come in capacities ranging from 275 to 330 gallons (1041 to 1249 liters). Constructed from molded or high-density polyethylene, these containers are durable and comply with ISO and national standards. IBC tote bins serve as an efficient alternative to barrels, drums, and other cumbersome containers. Their impressive capacity, mobility, and robustness make them ideal for transporting a variety of materials, including hazardous and volatile substances.
Folding IBC totes are constructed from sturdy molded polypropylene plastic and are designed to be collapsible and stackable. These totes come in various styles, including versions with and without tops, and feature a pallet-sized base similar to that used with IBC tote bins. They are available in a range of heights to suit different materials and applications. While folding IBC totes share features with IBC tote bins, such as a pallet base for easy access with forklifts or pallet jacks, they differ in that their rigid sides can collapse and fold over the base, facilitating easier handling and storage.
The IBC tote bin is the most prevalent and widely utilized type, known for its durability, strength, reusability, and safety. Besides IBC tote bins and collapsible plastic totes, there are various other types of IBC totes made from metals and fabrics. These alternative totes offer similar storage functions but tend to be less flexible and heavier. Their construction materials can make them more challenging to store, stack, and manage. These alternatives are primarily used for specialized applications, such as handling explosive or hazardous substances.
A distinctive type of IBC tote is the IBC tote tank, which resembles a traditional tank mounted on a pallet-style base. Unlike IBC tote bins, IBC tote tanks lack a metal frame and are constructed from high-strength polyethylene. These bulk containers offer a capacity of 550 gallons (2082 liters), equivalent to ten 55-gallon drums. Large IBC tote tanks are produced using rotational molding, which ensures a seamless, single-piece construction.
Similar to IBC tote bins, IBC tote tanks serve as an alternative to conventional drums, offering greater capacity and durability. They feature a cross-directional pallet base that facilitates easy handling and transportation. The design of IBC tote tanks includes essential components such as a threaded cap for loading, a vacuum relief vent, and an unloading valve.
IBC totes are designed to integrate with equipment, processes, and systems for efficient filling and emptying. IBC tote bins are equipped with taps, valves, caps, and fittings that facilitate access to their contents. These fittings come in various types, including male cams, female cams, horsetails, national pipe threads (NPT), and British standard pipe (BSP) threads.
The few IBC totes and bins that are described here are a small sampling of the many types of IBC tote bins that are available. IBC totes are a cost-effective method for transporting and storing a wide variety of products. Cube shaped IBC totes have a pallet sized base for easy stacking, shipping, conveying, and forklift entry. They come in rigid and flexible designs with flexible IBC totes being collapsible for storage and efficient use of space. As the types of liquid, granular, and powder products change, new and improved IBC tote bins are being developed to meet the ever changing needs.
To those outside the plastic container industry, bins and totes often seem identical and are used interchangeably. Both types of containers share a box-like shape, which contributes to this perception. They are constructed from similar robust, high-density plastics, ensuring durability and long-lasting use. However, despite their comparable appearances and materials, there are distinct differences between bins and totes, particularly in how they are utilized.
The primary distinction between bins and totes lies in their intended applications. Totes are designed to withstand the demands of industrial and manufacturing settings. They are essential for handling tasks such as transporting, safeguarding, carrying, and relocating various parts, components, products, and materials.
Although bins are constructed from the same durable plastics as totes, they feature an open design that allows for easy access by hand or tools. Bins are typically stationary and play a crucial role in organizing items. They are commonly used in parts storage areas and cages where quick retrieval of components is vital for smooth operation. Unlike certain totes, bins generally do not have a collapsible design.
Totes are often utilized for transporting or storing oversized and heavy objects. They come in various designs to accommodate large, bulky items that won't fit into standard bins. While totes can handle significant volumes, they are not designed for the easy retrieval of contents. In contrast, bins provide openings of different sizes for easier access but are generally not suited for holding very large items.
Choosing between a bin and a tote starts with considering the need for transportation. If the item will need to be moved frequently, a bin would not be suitable. Conversely, for small to medium-sized items that require regular access, a tote would not be ideal, making a bin the better choice. The key differences between bins and totes lie in their accessibility and mobility features.
Totes are well-suited for transporting items, whether across a store floor or over long distances. Their design, with four sides and the ability to be securely closed, makes them suitable for containing liquids and granular substances. Despite their durability and capacity, accessing items in totes requires more effort compared to other containers, as their contents are not as readily accessible.
The large or small opening of a bin makes access to its contents easy and convenient. Bins can be placed on shelves at a workstation, such as a workbench, for easy access to parts. They make small to medium parts quick and easily accessible to enable workers to efficiently complete an assembly or repair. Due to the open nature of bins, they are not a good choice for transporting items in any fashion.
Tote manufacturing involves various methods that depend on the tote's size, the type of plastic used, and the design. The production process for plastic totes is similar to that of other plastic containers. However, plastic totes are generally larger than typical plastic products, such as bottles and boxes, which leads to some differences in the production process.
Rotational molding is used for the manufacture of large totes such as IBC totes and other bulk totes. Known as rotomolding, rotomold, and rotocasting, the process is used to form hollow containers of any size and involves three stages, which are loading the mold with plastic resin, rotating the sealed mold in a high temperature oven, and the cooling station before unloading.
In rotomolding, the process begins with a mold that consists of two halves, into which plastic resin is introduced. The resin's type and quantity affect the tote's wall thickness and features like reinforcing ribs. A measured amount of resin is placed in one mold half, which is then attached to a rotating frame. This frame spins approximately every 90 seconds to ensure the resin is evenly spread across the mold's interior walls. The spinning frame and mold are then placed in a large oven where heat is applied to melt the resin and form the tote.
Once the mold has been heated for the required duration, it is transferred to a cooling chamber. In this chamber, the frame continues to rotate while cold water is sprayed onto the mold to aid in cooling. After the mold reaches the desired temperature, it is moved to the workers' platform for unloading and is then sent for additional processing.
Injection molding is a technique where molten plastic is injected under high pressure into a mold to create products. This method is ideal for high-volume production, enabling the creation of hundreds or even thousands of items in a short amount of time. The injection molding machine is comprised of two main components: the clamping unit and the injection unit. The clamping unit secures the mold for the tote and operates by opening and closing to allow the totes to be formed and cooled.
In the injection unit, plastic is melted and pushed into the mold to ensure it fills every part of the cavity. A key component in this process is the screw, which heats and propels the plastic towards the mold. This screw is the primary element of the injection system and plays a vital role in ensuring the plastic is adequately heated and evenly distributed throughout the mold.
Injection molding creates totes with precise tolerances and consistent design features, ensuring uniform wall thickness throughout. The injection mold is a precisely engineered cavity that mirrors the tote’s exterior. Crafted from hardened steel, this mold includes an ejection system that efficiently removes the completed tote.
Blow molding is divided into three processes, each of which uses a different method for injecting molten plastic into a mold. The types of blow molding are extrusion, injection, and injection stretch molding. Regardless of the type of blow molding, the basic principles of the process are the same, which is to inject molten plastic into a mold using compressed air that spreads the plastic material to the sides of the mold.
Blow molding starts with creating a shape known as the parison, which is crucial to the blow molding process. After the parison is produced, it is transferred into a mold. A tube attached to the mold directs air into the parison, causing the plastic to spread against the mold’s interior. As the air inflates the parison, the plastic takes on the mold’s shape.
Blow molding processes are known for their brief cycle times, allowing rapid production irrespective of the blow molding method used. Injection blow molding is efficient for high-volume production and features a core pin that rotates during both inflation and cooling. On the other hand, injection stretch blow molding is a more intricate process involving multiple stages and is the most durable among blow molding techniques.
The manufacturing of plastic containers involves a variety of plastics suitable for making plastic totes. The choice of plastic affects the tote's application, as lower density plastics may not withstand the rigors of shipping, distribution, or industrial processes. Engineers and designers who develop the specifications for these bins carefully assess the intended industry and the required strength of the tote.
Among the various plastics utilized in tote production, polyethylene types are the most frequently chosen. This category includes Low-Density Polyethylene (LDPE), Linear Low-Density Polyethylene (LLDPE), High-Density Polyethylene (HDPE), and Ultrahigh Molecular Weight Polyethylene (UHMW). These polyethylene variants allow manufacturers to select the most suitable plastic based on the specific needs of the tote.
Among polyethylene types, LDPE stands out for its flexibility and distinct flow characteristics. It has high density but low strength, making it suitable only for household totes. LDPE's low tensile strength results from its relatively weak intermolecular bonds. However, its impact resistance and durability make LDPE an excellent choice for home storage solutions.
HDPE is a highly versatile plastic, widely utilized in the manufacture of various plastic containers, including totes. Its popularity stems from its excellent tensile strength and favorable strength-to-density ratio. Key features of HDPE include its superior impact resistance and high melting point, which help it withstand demanding and high-stress environments.
Among the various plastics used for making totes, HDPE is one of the most ideal choices. It is a low-maintenance, durable material that offers safety and longevity. With a density ranging from 0.93 to 0.97 g/cm³, HDPE provides a blend of strength, cost-effectiveness, and environmental friendliness, making it suitable for a wide range of industrial applications.
PVC, or polyvinyl chloride, is a durable plastic created by combining vinyl chloride with phthalates and bisphenol-A. This mixture results in a flexible yet strong material. PVC is widely used in piping systems found in homes built over the past fifty years. Its popularity for making totes is due to its versatility, strength, lightweight nature, and resistance to environmental factors such as ozone, UV rays, and corrosion.
PET, or polyethylene terephthalate, is a widely used plastic for tote manufacturing due to its moldability. It is particularly favored in the food industry because of its safety and desirable physical characteristics. PET is energy-efficient to produce, lightweight, robust, and durable, and it requires less material to create a tote compared to other plastics.
Polyethylene terephthalate (PET) is produced through a reaction between terephthalic acid and monoethylene glycol (MEG). This reaction creates the monomers that make up the PET polymer. Following this process, PET is transformed into long, thread-like strands, which are then shaped into totes using various extrusion techniques.
Polypropylene is a versatile plastic known for its flexibility and adaptability through various manufacturing techniques. It can achieve strengths comparable to some metals. There are two primary types of polypropylene: homopolymers and copolymers. Homopolymers consist of propylene monomers arranged in a semi-crystalline structure, while copolymers are made by combining propene with ethene. Among these, homopolymers are generally tougher and more resistant to impact.
Polypropylene is favored for tote production because of its low melting point, which facilitates easy injection molding. This low melting point ensures that polypropylene flows smoothly during the molding process, making it ideal for manufacturing.
Over the past two decades, the popularity of plastic totes has surged due to their superior durability and longevity compared to cardboard boxes. The main advantage of plastic totes is their resilience, allowing them to adapt to various conditions. Initially, there were concerns about their environmental impact, with doubts about the recyclability of the plastics used. However, once it was established that the plastics used in totes are highly recyclable, their use expanded across different sectors.
Other types of storage containers may be vulnerable to moisture, bacteria, and loss of structural strength. Metal totes, while sturdy, are prone to rust unless they receive a protective coating during production. Advances in plastic manufacturing have made plastic totes resistant to these environmental issues. Once a plastic tote is emptied, it can be quickly cleaned and reused across various industries.
The primary advantage of plastic totes is their exceptional durability, which ensures longevity and cost-effectiveness. In today’s fast-paced business environment, equipment often faces significant wear and tear, leading to frequent breakdowns of less sturdy items. This is why many companies rely heavily on plastic totes, valuing their strength and reliability as a smart investment for cost savings and dependability.
Among various tools used in industrial, residential, and manufacturing settings, plastic totes stand out as the most economical option. They are manufactured quickly and offer exceptional durability, making them suitable for repeated use across numerous applications. Their long lifespan and amortizable cost over time further lower the initial investment. Plastic totes are versatile, fitting a range of needs from storage and transportation to supply, distribution, and warehousing.
Effective supply chain management relies on organization, accessibility, and efficiency. Plastic totes have become increasingly popular for enhancing warehouse and stock room organization. Their lightweight, maneuverable, and compact design allows them to accommodate a variety of items, from engine components to small plastic fasteners, making them a versatile storage solution.
Warehouse managers understand that efficient space utilization is both cost-effective and crucial. Unlike cardboard boxes, plastic totes are both sturdy and compact. Their space-saving design allows for efficient use of rack space, enabling multiple totes to fit in a single rack. Additionally, their stackable nature and capacity to support heavy loads further contribute to maximizing storage space.
Plastic totes are engineered for repeated use without compromising their strength or quality. This durability contributes to cost savings, as the cost per unit decreases with each use. Their long lifespan is attributed to their resistance to impact, corrosion, and contamination by bacteria or pests.
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