Monoflo International is expanding its distribution and fulfillment portfolio with the launch of two new Attached-Lid Tote models engineered to deliver improved durability, efficiency and sustainability in high-cycle operations.

DC 2420-12 SP1

The DC 2420-12 SP1 advances our 24x20x12 platform with a series of meaningful engineering improvements. A new all-plastic hinge replaces the previous metal pin design, improving safety, recyclability and long-term reliability. Newly added load-bearing nesting ribs help distribute stack weight more efficiently, reducing bottom deformation and extending container life. The model also features our reinforced bumper system, ergonomic handles and optimized nesting profile—delivering consistent, high-performance handling in demanding distribution environments.

DC 2820-15 SP1

The new DC 2820-15 SP1 brings enhanced performance to the prevalent 28x20x15 footprint used across today’s distribution operations. A material-efficient, high-strength design supports improved ergonomics and sustainability, while a reinforced bumper system and updated lid detents enable easier handling and extended lid life. An all-plastic hinge enhances safety and recyclability, delivering a durable, user-focused solution that integrates seamlessly into existing fleets.

Both totes are available with a full range of tracking and identification options—barcodes, license plates, RFID, label areas and custom hot stamps—along with optional drain-hole bottoms, recycled content and color customization.

Plastic automation totes and trays are a critical component of any automated system. They are the standard alternative to corrugated boxes that don’t convey well at high speeds and can be easily damaged, causing product loss, operational inefficiencies, and resulting in unnecessary waste.

Plastic automation totes are clean and hygienic, eliminating dust and fibers that can result from totes made from other materials, and if they become soiled, can be easily washed, and quickly returned into use. Automation totes create the uniformity required across non-uniform items to optimize handling efficiency.

But there are many different types of plastic automation totes and tote manufacturers. When totes are not well selected for their function or poorly manufactured, they can be unnecessarily expensive or perform improperly to the point of continuous system failures. Below, we’ll discuss some of the top considerations that will influence your tote selection for automated systems.

Size & Customization Options

While every automated system is unique, there are many standardized tote footprints used across a variety of automated systems. Two of the most commonly used are the 600 mm x 400 mm and 650 mm x 450 mm footprints. Within each footprint, there are different height options, typically ranging from 220 mm to 440 mm. Depending on the system and the products that need to be accommodated in the container, custom sizes may be required.

Oftentimes, tote customizations other than size are required for a specific application. For example, barcode labels that uniquely identify a tote need to be in specific locations and readable on the container so the system can accurately read it.

Optional dividers or mini tote systems offer flexibility and allow for more efficient use of a container. Depending on the product that will be inside the tote, custom material blends, such as ESD (Electrostatic Dissipative), may also need to be considered.

Specifications & Tolerances for Automated Storage & Retrieval Systems

Tote requirements for an automated system leave very little room for error. Deviation from specs, even by a millimeter, can cause totes to get hung up in the system, potentially bringing operations to a halt.

The bottom of an automation tote is also critical to its performance. It impacts how well the tote moves throughout the distribution center as well as how the items contained within the tote will be supported. The wrong bottom can also contribute to unwanted noise in a facility.

Look for Quality, Repeatable Manufacturing

AS/RS can be tough handling environments for totes, so you’ll want to work with a manufacturer that understands how to produce a durable container that will continue to perform in the system for a long time.

Reliable repeatability is paramount to the success of a manufacturer of automation containers. A quality manufacturer will be able to consistently manufacture totes within the required specifications and without deviation. This means consistency between the first tote in an order to the last, and from one order to another. That consistency also extends to predictable cycle times, resulting in accurate production schedules and on-time deliveries.

Choose Monoflo for Automation Totes

Consistent, Quality Products

Monoflo has invested in cutting-edge technology that enables us to manufacture high-pressure injection molded automation containers fast and at a lower price while still adhering to the strictest of spec tolerances.

Our ISO 9001-2015 processes and state-of-the-art technology ensure every piece that comes off the line meets these specifications for the best possible performance, order after order. And our consistency in manufacturing translates into reliable totes, delivered on time for a seamless induction.

Industry Experts

With so many options and plastic automation tote manufacturers out there, it can be a challenge to sort through the noise and decide what’s best for your application. As we help our customers navigate their tote selection, we start by understanding what their need is.

What kind of system will this tote be inducted into? What type of products will be contained in the tote?

There are several considerations that contribute to selecting the appropriate container for the job, and you’ll want an experienced product and industry expert to help you work through them all.

Whether you’re building a new facility or inducting new totes into an existing facility, our experience and relationships with system integrators enable us to deliver exactly the tote that you need within the tolerances required to ensure a seamless induction into your system. Our automation container product lines include Stack Only Containers, Collapsible Containers, and Stack & Nest Containers. For more information or to learn about our automation tote offering, get in touch with our team today.

Plastic pallets are a staple product used in warehouses and distribution supply chains across the globe. They are designed for different purposes, applications, and industries, but not all pallets are created equal. Below, we review five factors you should consider when evaluating a distribution pallet.

5 Considerations When Selecting the Right Plastic Pallets for Distribution

1. Pallet Size

Standard-sized pallets have a GMA (Grocery Manufacturers Association) 48” x 40” footprint and are used throughout the food manufacturing and distribution industries. Other common footprints include the 30” x 42”, popular for direct-to-store applications, and the European standard (EUR1) size of 1200 mm x 1000 mm.

2. Load Capacity

Load capacity is how much weight a pallet can support in a given environment. Your pallet load capacity must meet or exceed the weight of the load you plan to put on your pallet. A pallet’s load capacity is predominantly influenced by design and material and are commonly evaluated in three ways: static, dynamic, and racking.

• Static Load Capacity measures how much weight a pallet can accommodate while stationary or stacked, while sitting on a warehouse floor, for example.
• Dynamic Load Capacity measures the maximum weight that can be evenly distributed while a pallet is being lifted or moved, usually by a forklift or hand jack.
• Racking Load Capacity is the maximum distributed weight a pallet can hold while in a racking system. With a range of racking types, including supported and non-supported, how much the pallet can handle will depend on the type of racking system available at your facility. It is always best to consult with a professional salesperson to discuss the best pallet for your specific application.

3. Pallet Durability

Durability is a significant factor to consider when evaluating the right pallet for an application. Pallets that aren’t designed for heavy loads can break, potentially damaging the product they are carrying or posing a hazard to employees, impacting productivity and workplace safety. Additionally, pallets made of certain materials break more easily than other pallets. For example, structural foam pallets are brittle due to air pockets that are created during manufacturing, so they are more susceptible to breakage and failure.

4. Cleanliness

Depending on the product placed on the pallet, or the facility where the pallet is used, some pallet designs or materials are not well suited for the application. For example, facilities in food processing or pharmaceutical manufacturing must adhere to strict cleanliness requirements. Injection molded plastic pallet’s smooth, non-porous surface is resistant to pest infestation and bacteria growth, making them ideal for cleanroom applications.

5. Overall Pallet Cost

Selecting the pallet with the lowest upfront cost can be tempting, but if it falls short in areas like the ones we’ve just discussed, you may pay more in the long run. These hidden costs are often incurred in additional freight, efficiency or productivity loss, equipment or product damage, employee injuries, and replacing broken pallets. It may be worthwhile to spend more upfront for a better-performing, longer-lasting pallet that will be more cost-effective over time.

Benefits of Injection Molded Plastic Pallets for Distribution

Injection Molded Plastic pallets are well-known in the distribution industry for their light weight and extreme versatility. They offer durability, are safer, more hygienic, and have a lower cost of ownership than other options.

Durable & Strong

High-pressure injection molded pallets are more durable than many other plastic pallets on the market. They are designed to be impact resistant and can often remain in service even after impact from a fork tine. They also experience significantly less breakage than pallets made of structural foam, another commonly used material in pallet manufacturing.

Safe & Hygienic

High pressure injection molded plastic pallets are smooth and non-porous, making them resistant to microbial growth, chemical contamination, and pest infestation. Many plastic distribution pallets are also designed to be easily washed and put back into use quickly. And because plastic pallets are lightweight, won’t splinter, and don’t contain sharp metal, they are safer for employees who work with and handle them every day.

Sustainable

Plastic pallets have a much longer lifespan than pallets made from other materials. Once they reach the end of their life, they can be easily recycled for use in new products. Plastic pallets can also be manufactured using recycled material. This helps to reduce waste and ensure a more sustainable packaging system.

Cost-Effective

Injection molded plastic pallets are light weight and manufactured using less material, resulting in freight savings beginning with their first delivery. While plastic pallets may carry a higher upfront cost, it is quickly recouped for most facilities through improved operational efficiency, reduced product damage, and longer service life. Customers quickly realize the upfront investment in injection molded plastic pallets, and ROI is easily seen.

Why Monoflo for Plastic Pallets for Distribution

An Industry Leader

Monoflo’s continued investment in technology allows us to deliver a superior, more reliable pallet that sets us apart from our competition. We hand select only the best-in-class robotics and machinery to automate our manufacturing processes and optimize efficiency. This translates into cost savings that enable us to provide better performing, premium-quality pallet at a competitive price.

Industry Experts

Monoflo employs a curated team of experienced, highly-trained engineers and designers, as well as industry experts with a deep understanding of our customers’ business. Our team provides individualized attention to help our customers optimize their packaging strategy and overcome challenges they’re facing.

Wide Variety & Customization Options

Monoflo’s high-pressure injection molded pallets offer the highest strength-to-weight ratios, making them perfect for the distribution industry. Our pallet product lines include Welded and Non-Welded Nestable Pallets, as well as Rackable and Stackable Pallets.

• Nestable 48” x 40” Injection Molded Welded G2 Pallet has a two-piece welded design with enhanced internal deck ribbing that delivers strength and durability with low tare weight, offering superior handling of heavier loads.
• Nestable 48” x 40” Injection Molded Pallet This nestable plastic pallet is designed around a footprint for GMA applications. This pallet is designed for storage or shipment of distribution and retail goods, as well as high-end export needs.
• Nestable 1200 mm x 1000 mm Injection Molded Pallet is designed around an EUR 2 footprint, an international standard. It is a one-piece, high-pressure injection molded pallet, and its slightly smaller footprint lends itself to retail applications.
• Nestable 30” x 42” “Half” Pallet is an ideal pallet for retail and direct store delivery applications. It is specifically designed to fit through a standard doorway, and pallet’s lightweight design and ergonomic handles improve handling safety and efficiency.

All of the pallets mentioned above are 100% recyclable and available in recycled material.

If you’re looking for plastic pallets for distribution, Monoflo has what you’re looking for. Our wide variety of pallets are designed to suit your application requirements, and our industry experts can help you identify the most effective solution to address your performance needs. For more information or to check out our plastic pallet products, get in touch with our team today.