Corrugated cardboard has long been a reliable and commonly used packaging material. Known for its recyclability and availability, it plays an important role in many warehouse operations. However, for companies looking to extend the lifecycle of their materials and enhance sustainability efforts, alternative solutions like Wave-Core—crafted from HDPE plastic—offer compelling advantages.
Enhancing Warehouse Sustainability
While corrugated cardboard is recyclable and widely used, warehouses that rely heavily on single-use materials may find opportunities to further improve their sustainability strategies. In the U.S., about 42 million tons of corrugated cardboard are used annually, with 33 million tons recycled. By complementing existing recycling practices with more durable materials, warehouses can better align with ESG initiatives and reduce waste.
Wave-Core, made from high-density polyethylene (HDPE), supports a circular approach by offering repeat use across thousands of production cycles. This makes it an excellent option for organizations looking to reduce material turnover and waste in daily operations.
The Benefits of HDPE with Wave-Core
Wave-Core is engineered to endure rigorous warehouse environments, offering superior longevity compared to traditional packaging materials. HDPE can be recycled up to 10 times and is accepted at many recycling centers, making it both a durable and sustainable choice.
From packaging to storage, inventory management, and materials handling, Wave-Core enables facilities to reduce the frequency of material replacement and minimize operational waste. The result is a more efficient workflow and a measurable reduction in environmental impact over time. That makes Wave-Core a great option for reducing costs and your carbon footprint.
Understanding the benefits of corrugated HDPE Plastic
HDPE plastic stands for High-Density Polyethylene. Its tightly packed molecular structure lends this material the rugged durability for which it is well-known.In a warehouse application, Wave-Core provides a wide range of versatile options that rival that of cardboard. Here are some of the ways we can customize Wave-Core.
- Dual-layer and triple-layer options, both featuring a wave-like core for strength reinforcement.
- Can be customized to enhance strength, as well as your desired level of rigidity and flexibility, without adding thickness.
- Customization with die-cutting, sonic welding and metal wires and fasteners.
- Embossing, printing and colors for branding, sorting and other functions.
Warehouse applications for Wave-Core
There are multiple opportunities where corrugated HDPE can be used in place of corrugated cardboard to help warehouse operations reduce material waste and work more efficiently. Here are a few possibilities.
Heavy duty packaging
Achieve better protection for fragile or high-value items with Wave-Core. It’s impact resistance and shock absorption properties reduce breakage during shipping, while also shielding materials from moisture and other environmental elements.
Read our case study: Wave-Core™ Prevents Damage and Cuts Costs For Stone Manufacturer.
Outdoor storage and transportation
Protecting lumber, spools of film and other raw materials from the elements is a sure way to cut costs and reduce waste.. Covers and wraps made from Wave-Core provide a protective barrier against UV damage, frost, wind, rain and more.
Read our case study: Wave-Core™ Prevents Damage During International Transportation
Materials handling
Automation is increasingly adopted in warehouse management. That calls for bins and containers that are durable enough to withstand multiple production cycles of machine interface. Rugged bins made from Wave-Core provide the solution for increasing turns and reducing downtime.
Read our case study: Liberty Plastics Increases Turns 8,000% for Large Food Manufacturer
Inventory management
Long-lasting bins and shelving made from Wave-Core keep supplies and materials organized. Custom coloring and printing make ID and sorting effortless.
For additional possibilities and insights, read our blog, 6 Ways to Use and Reuse Wave-Core to Streamline Procurement and Boost Your Bottom Line.
Environmental and cost benefits of switching to corrugated HDPE Plastic
Switching from traditional packaging materials to corrugated HDPE plastic, such as Wave-Core™, offers substantial long-term advantages for your warehouse operations—both environmentally and financially.
Environmental
Corrugated HDPE like Wave-Core™ delivers a longer lifecycle and improved reuse potential, significantly reducing the overall volume of packaging material required over time. This means fewer resources consumed and less material ultimately entering the waste stream. With measurable reductions in material use, your organization can showcase its commitment to sustainability and highlight real progress in lowering carbon emissions and energy usage.
Cost Advantages
While the initial investment in HDPE plastic may be higher, its extended durability and reusability lead to significant long-term savings. The reduced need for frequent repurchasing and the minimization of disposal costs contribute to a lower total cost of ownership. Over time, the switch to HDPE can improve operational efficiency and deliver clear financial returns.
How to get started
Reducing single-use cardboard in your warehouse is a process that includes analyzing the environmental and cost benefits of switching to Wave-Core, getting buy-in from the team, and collaborating with Liberty Plastics to design and fabricate your solution.
Conduct a cardboard waste audit
Transitioning to corrugated HDPE begins with a thoughtful evaluation of your current packaging needs. Review the potential environmental and financial impacts of adopting Wave-Core™, engage your team in the decision-making process, and partner with Liberty Plastics to create a custom solution tailored to your workflow. With the right approach, you can enhance sustainability and efficiency across your warehouse operations.
To learn more, read our blog, Productivity has a silent killer - A surprising way manufacturers accrue unplanned downtime.
Collaborate with staff on the benefits of HDPE corrugate
As you identify new applications for Wave-Core that can take the place of corrugated cardboard, you’ll want to factor in training and education on how to use this new material in the workday. To increase participation and buy-in, provide incentives for those who submit ideas that reduce waste and improve productivity.
Design your solution with Liberty Plastics
Once you have some concepts in mind, our team can help you bring them to the finish line. We’ll consult with you to design and fabricate your packaging solutions. We can produce prototypes so you can test run new concepts and make sure they’ll work with your operation as expected.
From design to fabrication, Liberty Plastics provides all-inclusive services to create solutions from Wave-Core to enhance your operation’s sustainability, efficiency and cost-saving efforts. To get started, contact our team today!