EFFICIENCY OPTIMIZATION OF REUSABLE STYROFOAM BOXES IN THE CHILLED PRODUCT TRANSPORTATION PROCESS: A CASE STUDY OF A FROZEN FOOD LOGISTICS COMPANY
Keywords:
Returnable Packaging, Cold Chain Logistics, Reverse Logistics, Process ImprovementAbstract
The objectives of this research were: 1) to study the rotation, sorting, inspection, and recording systems for the reuse of foam boxes in the chilled product transportation process; 2) to analyze the causes of foam box deterioration in terms of cooling retention efficiency and the inability to reuse the boxes; and 3) to develop methods for improving the cooling retention performance of foam boxes and enhancing their cost-effective reuse in a case study company. This study employed an action research and development approach for process improvement by applying the Deming Cycle (PDCA) together with logistics management principles. The research tools included a Flow Process Chart, a Fishbone Diagram, an A/B/C Packaging Grading System, Standard Operating Procedures (SOPs), and foam box data recording sheets.
The findings revealed that the main causes of rapid foam box deterioration and the risk of temperature loss in chilled products were the lack of a standardized sorting system, which resulted in usable and damaged boxes being mixed together; inconsistent visual inspection based on individual judgment; and the physical limitations of the material, which deteriorated rapidly after only 2-3 reuse cycles. Therefore, the researchers implemented a new system through four key improvement steps. The comparative results after system improvement showed successful outcomes according to the specified indicators. Foam boxes lined with thermal foil increased cooling retention from 2-3 hours to 4-6 hours. The reuse rate increased from 30% to 40%-50%, resulting in a reduction in the number of damaged foam boxes from 10-15 boxes per month to only 5-8 boxes per month. In addition, the cost of purchasing new foam boxes was reduced by at least 20%-30% from the previous cost of 6,000-7,000 baht per month. The new system also reduced the time required to search for usable boxes from 5-10 minutes per instance to only 1-3 minutes per instance. The warehouse was better organized through zoning, and the rate of temperature loss in chilled products during transportation was reduced to only 3-5 cases per month. This research can be applied as a model for operators with similar contexts.
References
สิริพงศ์ เพ็ญสิริพงศ์. (2565). รูปแบบการส่งคืนภาชนะใช้ซ้ำได้สำหรับการสั่งอาหารออนไลน์. [สารนิพนธ์ปริญญามหาบัณฑิต]. จุฬาลงกรณ์มหาวิทยาลัย. https://doi.org/10.58837/CHULA.IS.2022.218
Accorsi, R., Cholette, S., Manzini, R., & Mucci, L. (2022). Managing uncertain inventories, washing, and transportation of reusable containers in food retailer supply chains. Sustainable Production and Consumption, 31, 331-345.
https://doi.org/10.1016/j.spc.2022.02.014
Bradley, C. G., & Corsini, L. (2023). A literature review and analytical framework of the sustainability of reusable packaging. Sustainable Production and Consumption, 37, 126-141.https://doi.org/10.1016/j.spc.2023.02.009
Ceballos-Santos, S., De Sousa, D. B., García, P. G., Laso, J., Margallo, M., & Aldaco, R. (2024). Exploring the environmental impacts of plastic packaging: A comprehensive life cycle analysis for seafood distribution crates. Science of the Total Environment, 951, Article 175452.https://doi.org/10.1016/j.scitotenv.2024.175452
Goellner, K. N., & Sparrow, E. M. (2014). An environmental impact comparison of single-use and reusable thermally controlled shipping containers. The International Journal of Life Cycle Assessment, 19(3), 611-619.
https://doi.org/10.1007/s11367-013-0668-z
Kim, S. Y., Kang, D. H., Charoensri, K., Ryu, J. R., Shin, Y. J., & Park, H. J. (2023). Comparative life cycle assessment of reusable and disposable distribution packaging for fresh food. Sustainability, 15(23), Article 16448.
https://doi.org/10.3390/su152316448
Rahman, M. M., Sikandar, M. U., Chowdhury, P., Roy, S., & Khrystoslavenko, O. (2025). Toward sustainable cold chain packaging: A systematic review of insulating materials and green alternatives for temperature-sensitive logistics. International Journal of Multidisciplinary - Development, Perspectives & Innovation,
(3), 1-13.
Ren, T. (2024). Research on cold chain packaging risk management based on fuzzy Bayesian network and TOPSIS. [Doctoral dissertation]. Liverpool John Moores University. https://researchonline.ljmu.ac.uk/id/eprint/24577/
Ren, T., Ren, J., Matellini, D. B., & Ouyang, W. (2022). A comprehensive review of modern cold chain shipping solutions. Sustainability, 14(22), Article 14746. https://doi.org/10.3390/su142214746
Rogers, D. S., & Tibben-Lembke, R. S. (1999). Going backwards: Reverse logistics trends and practices. Reverse Logistics Executive Council.
Singh, S. P., Burgess, G., & Singh, J. (2008). Performance comparison of thermal insulated packaging boxes, bags and refrigerants for single-parcel shipments. Packaging Technology and Science: An International Journal, 21(1), 25-35.
https://doi.org/10.1002/pts.773
Thoroe, L., Melski, A., & Schumann, M. (2009). The impact of RFID on management of returnable containers. Electronic Markets, 19(2), 115-124. https://doi.org/10.1007/s12525-009-0013-3
Vivaldi, F., Melai, B., Bonini, A., Poma, N., Salvo, P., Kirchhain, A., Tintori, S., Bigongiari, A., Bertuccelli, F., Isola, G., & Di Francesco, F. (2020). A temperature-sensitive RFID tag for the identification of cold chain failures. Sensors and Actuators A: Physical, 313, Article 112182. https://doi.org/10.1016/j.sna.2020.112182
