Custom Solutions
When standard containers do not fit your needs, our engineering and consulting team designs packaging solutions tailored to your exact specifications.
Packaging Engineered for Your Needs
Not every packaging challenge has an off-the-shelf answer. Unusual product dimensions, extreme weight, regulatory requirements, or complex supply chain logistics can all demand a custom approach.
Our Custom Solutions team combines decades of packaging engineering experience with our extensive network of container manufacturers and material suppliers. We design, prototype, test, and deliver packaging systems that solve your specific challenges -- whether that means a custom-sized IBC tote, a specialized IBC tote configuration, or a complete returnable container program.
And because we are also recyclers, sustainability is built into every solution we design. We prioritize reusable, recyclable, and right-sized packaging that minimizes waste and environmental impact from day one.
Our Custom Capabilities
From a simple size modification to a complete packaging system design, here is what our custom solutions team delivers.
Custom Sizing
Standard sizes do not always fit non-standard products. We design and source custom-dimensioned containers that match your exact product footprint, maximizing cube utilization and minimizing wasted space. Whether you need an odd-width IBC tote, a non-standard tank, or a container with unusual height requirements, we can deliver.
Example Projects
- Oversize IBC totes for large automotive assemblies
- Custom-dimensioned totes for specialized rack systems
- Extra-deep containers for lightweight, high-volume products
- Compact totes for retail display staging
Specialized Packaging
Some products demand more than a standard box. Our specialized packaging services combine container selection with custom interior configurations -- foam inserts, molded liners, custom dividers, and anti-static materials -- to create packaging systems that protect sensitive, fragile, or high-value items throughout the supply chain.
Example Projects
- ESD-safe packaging for electronics and circuit boards
- Foam-lined containers for precision machined parts
- Multi-product packaging with custom divider configurations
- Temperature-controlled packaging with insulated liners
Consulting Services
Our packaging consultants bring decades of industry experience to help you optimize your container strategy. We audit your current packaging, identify waste and inefficiency, and recommend solutions that reduce cost, improve product protection, and support your sustainability goals.
Example Projects
- Packaging audits to identify cost-saving opportunities
- Sustainability assessments for ESG and compliance reporting
- Supply chain optimization for container flow and logistics
- Vendor consolidation to simplify procurement
Industry-Specific Solutions
Different industries have different packaging challenges. We develop solutions informed by deep knowledge of regulatory requirements, handling environments, and material compatibility for sectors ranging from food and pharmaceuticals to automotive and heavy manufacturing.
Example Projects
- FDA-compliant packaging for food and pharmaceutical products
- ISTA-tested designs for fragile goods in transit
- Returnable container programs for automotive supply chains
- Hazmat-compliant packaging for chemical and industrial materials
Design & Engineering
Our in-house design and engineering team uses CAD modeling and structural analysis to develop packaging solutions from concept through production. We prototype, test, and refine designs to ensure they meet your performance specifications before you commit to a full order.
Example Projects
- CAD-modeled container and insert designs
- Structural analysis for stacking and load-bearing requirements
- Prototype development and physical testing
- Material selection optimization for cost and performance
Container Modification Services
Sometimes you do not need a container built from scratch -- you need an existing container modified to fit your specific requirements. Our modification services transform standard containers into purpose-built solutions.
Cutting & Resizing
We cut down IBC totes and tanks to custom dimensions. Heights, widths, and lengths modified to your exact specifications.
Liner Installation
Food-grade, chemical-resistant, anti-static, or moisture-barrier liners installed in any container type. Welded, glued, or removable options.
Custom Labeling
Branded labels, barcodes, QR codes, safety warnings, and handling instructions applied to containers. Permanent or removable adhesive options.
Drain & Valve Modification
IBC totes modified with upgraded valves, different spout sizes, quick-connect fittings, or additional drain ports for your specific process.
Reinforcement
Additional structural reinforcement for heavy loads, stacking, or rough handling. Corner bracing, bottom supports, and wall strengthening available.
Partition & Divider Installation
Custom internal dividers, partitions, and compartments installed to separate products, prevent shifting, and organize contents.
Industry-Specific Expertise
Every industry has unique packaging challenges. We bring specialized knowledge to each sector we serve, understanding the specific regulations, handling requirements, and performance needs that define your industry.
Automotive
Food & Beverage
Pharmaceutical
Electronics
Heavy Manufacturing
Agriculture
Chemical & Petrochemical
Aerospace & Defense
Medical Devices
Retail & E-Commerce
Inventory Management Programs
For businesses with ongoing custom container needs, we offer managed inventory programs that ensure you always have the containers you need without the burden of warehousing large quantities on-site.
Safety Stock
We maintain a safety stock of your custom containers at our facility, ready to ship on short notice. Never run out of the packaging you depend on.
Vendor Managed Inventory
We monitor your usage patterns and proactively trigger production and delivery before you run low. You never need to reorder.
Kanban / JIT Delivery
Containers delivered in precise quantities on a just-in-time schedule, minimizing your on-site inventory and warehouse space requirements.
Consignment Programs
For qualified accounts, we stock containers at your facility on consignment. You only pay for what you use. Inventory remains our property until consumed.
Implementation Timeline
From initial discovery to production delivery, here is our typical project timeline. Simple modifications may take as little as 2-3 weeks. Complex custom designs typically run 8-16 weeks.
Discovery
1-2 weeksWe start by understanding your products, your supply chain, and your pain points. This includes on-site visits, product measurements, and detailed discussions about your operational requirements and constraints.
Concept Development
1-2 weeksOur engineers develop initial concepts using CAD modeling, considering material options, structural requirements, and cost targets. We present multiple options so you can choose the direction that best fits your priorities.
Prototyping
2-3 weeksWe build physical prototypes for hands-on evaluation. You test them in your actual operational environment with your actual products to verify fit, function, and durability before committing to production.
Testing & Refinement
1-3 weeksBased on prototype feedback, we refine the design. This may include structural testing (compression, vibration, drop), environmental testing (humidity, temperature), or field trials in your facility.
Production Planning
1-2 weeksFinalized designs enter production planning where we select manufacturing partners, negotiate pricing, establish quality control checkpoints, and set delivery schedules.
Manufacturing & QC
2-6 weeksProduction begins with in-process quality inspections at every stage. First-article samples are approved before full production proceeds. We manage the entire manufacturing process on your behalf.
Delivery & Implementation
1 weekFinished containers are delivered to your facility. Our team provides on-site training for your staff on proper use, handling, and maintenance of the new packaging system.
Custom Solutions in Action
Real examples of how our custom engineering solves real packaging challenges.
Returnable Container Program Saves $320K Annually
Designed a custom returnable container system for shipping transmission components between plants. The containers replaced single-use wood crates, reducing packaging cost by 72% and eliminating 180 tons of wood waste per year.
Custom Packaging Reduces Damage Rate to Near-Zero
Engineered a foam-insert system for shipping precision surgical instruments. The custom design replaced generic bubble wrap, reducing product damage from 4.2% to 0.1% and saving $156,000 in annual warranty claims.
ESD-Safe System Eliminates Static Damage Claims
Developed a complete ESD-safe packaging system for circuit board shipping across 3 facilities. Conductive foam inserts, anti-static containers, and humidity control eliminated all static-related damage, which had been costing $89,000 per year.
Why Invest in Custom Packaging?
Less Damage
Right-sized, purpose-built packaging significantly reduces product damage during storage and transit.
Space Savings
Custom-sized containers eliminate wasted void space, fitting more product per unit and per truck.
Freight Savings
Better cube utilization means fewer trucks, fewer trips, and lower transportation costs.
Fit for Purpose
Every aspect of the packaging is designed around your product and your workflow, not the other way around.
Frequently Asked Questions
How much does a custom solution cost?
Costs vary widely based on complexity. Simple modifications (cutting, lining, labeling) can cost as little as a few dollars per container. Full custom designs with engineering, prototyping, and production tooling range from $5,000 to $50,000+ depending on scope. The initial consultation is always free.
What is the typical timeline for a custom project?
Simple modifications can be completed in 2-3 weeks. Standard custom designs typically take 8-12 weeks from discovery to first production delivery. Complex projects with extensive testing may take 12-16 weeks. Rush timelines are available for critical needs.
Is there a minimum order quantity for custom containers?
Minimum quantities depend on the design and manufacturing method. Simple modifications have no minimums. Custom manufactured containers typically require minimum orders of 50-500 units depending on the complexity and tooling involved.
Do you provide prototypes before production?
Yes. Prototyping is a standard part of our process. We build physical prototypes for you to evaluate in your actual operating environment before committing to production. This ensures the design works for your specific application.
Can you modify existing containers we already have?
Absolutely. Our modification services include cutting, resizing, adding liners, installing dividers, reinforcing, relabeling, and more. Bring us your existing containers and we will adapt them to your needs.
Do you handle the entire process or just design?
We handle everything end-to-end: consultation, design, engineering, prototyping, testing, manufacturing, quality control, and delivery. You work with a single project manager who coordinates the entire process.
What industries do you specialize in?
We have deep experience in automotive, food and beverage, pharmaceutical, electronics, chemical, aerospace, medical devices, heavy manufacturing, agriculture, and retail packaging. Our team includes specialists with backgrounds in these industries.
Can you help with sustainability goals?
Yes. Sustainability is built into every custom design. We prioritize reusable, recyclable, and right-sized packaging. We can also design returnable container programs that eliminate single-use packaging entirely and provide documented environmental impact metrics.
What if the custom design does not work for our application?
That is why we prototype and test before production. If the first prototype does not meet your requirements, we refine the design at no additional cost until it works. Our goal is a solution that performs flawlessly in your real-world conditions.
Start Your Custom Project
Tell us about your packaging challenge and we will schedule a discovery conversation. There is no cost or obligation for the initial consultation.