System with primary and secondary circles for the reuse of shelf-ready secondary packaging

Abstract

The invention relates to a system (1) with at least one primary circle (1a) for the reuse of shelf-ready secondary packaging (10, 15) for the appropriate presentation and delivery of primary packaging (50) containing goods. The primary circle (1a) extends over a variety of separate and spatially separated buildings (20, 70, 80), between which the shelf-ready secondary packaging (10, 15) is transported by vehicles (60). The method further relates to a shelf-ready secondary packaging (10, 15), a transport box for transporting the shelf-ready secondary packaging (10, 15), and a method (100) for operating a system (1).

Description

[0001] 40261 / 4361 / PTWO 5 February 2025

[0002] 1

[0003] System with primary and secondary circles for the reuse of shelf-ready secondary packaging.

[0004] Field of the Invention

[0005] The present invention relates to a system with at least one primary circuit for the reuse of shelf-ready secondary packaging for the appropriate presentation and delivery of primary packaging containing goods. The primary circuit extends across a multitude of separate and spatially distinct buildings, between which the shelfready secondary packaging is transported by vehicles. Furthermore, the invention pertains to a shelf-ready secondary packaging, a transport box for the transportation of the shelf-ready secondary packaging, and a method for operating such a system.

[0006] Background of the Invention

[0007] Cardboard displays, also known as cardboard, stands or POS (Point of Sale) displays, are a common means of product presentation in discount stores and other retail outlets. It is estimated that 6 to 8 billion such cardboard displays are used annually in retail in Germany, for example, in grocery retail or drugstore retail. For Europe, the estimated number is around 30 billion cardboard displays.

[0008] Cardboard displays are primarily made of cardboard, which is inherently a highly recyclable material. After use, the displays are typically disassembled and placed in wastepaper disposal to reduce the amount of waste generated by used cardboard displays. The wastepaper is then processed in recycling facilities into new paper products. However, in many cases, the cardboard is also disposed of directly in general waste due to contamination. For Example: cardboard boxes are not reused in the food sector, mainly because they are often glued and cannot be compacted without being destroyed. Additionally, there is no way to clean them.

[0009] Existing recycling systems offer better environmental protection than single-use cardboard boxes; however, they remain energy and resource-intensive. Given the vast quantity of such cardboard packaging and displays, it would be desirable to further reduce the amount of cardboard displays that need to be recycled.40261 / 4361 / PTWO 5 February 2025

[0010] 2

[0011] Moreover, systems in the state of the art are already so advanced that incremental changes in individual steps of the system are not possible to significantly increase the system's efficiency. Therefore, it would be desirable to have an alternative recycling system parallel to the current state of the art that meets the same requirements but operates much more energy- and resource-efficiently.

[0012] Summary of the Invention

[0013] The objective of the invention is therefore to provide a system that reduces the vast amount of cardboard packaging and cardboard displays, while simultaneously replacing them with a suitable shelf-ready secondary packaging in conjunction with an effective and resource-efficient return and recycling system.

[0014] This is solved by a system with at least one primary circuit for the reuse of shelfready secondary packaging for the transport and suitable presentation and dispensing of goods-filled primary packaging, wherein the primary circuit extends over a plurality of separate and spatially separated buildings, between which the shelf-ready secondary packaging is transported by means of vehicles, comprising:

[0015] a plurality of these shelf-ready secondary packaging, each consisting of more than 50% by weight of a corrugated plastic material, wherein the shelf-ready secondary packaging is designed in two parts and comprises a one-piece foldable base consisting at least of a bottom and side walls surrounding the bottom with a display side, as well as a separate one-piece foldable lid, wherein the lid and base can be reversibly converted multiple times from a flat form to an erected form and back by folding along pre-formed fold lines, wherein the erected form of the base is intended for filling with primary packaging containing goods, and the lid is intended to be suitably assembled with the base to enclose the primary packaging as filled shelf-ready secondary packaging together with the filled base at least during transport, wherein the base and lid each comprise at least one identification element for uniquely identifying at least the types of base and lid and determining their positions in the system;

[0016] one or more first buildings for the automatic sorting, cleaning and / or preparation and / or providing of at least part of the returned used shelf-ready40261 / 4361 / PTWO 5 February 2025

[0017] 3

[0018] secondary packaging as reusable shelf-ready secondary packaging in separate processes for the bases and lids; • one or more second buildings for the erection, filling with primary packaging, and assembly of the bases and lids received separately in flat form from the first buildings into the filled shelf-ready secondary packaging with base and lid;

[0019] one or more third buildings for receiving the filled shelf-ready secondary packaging from the base and lid, removing the lids from the bases, and offering the primary packaging in the bases;

[0020] vehicles for transporting the shelf-ready secondary packaging between at least the first, second, and third buildings, wherein

[0021] (a) the bases and lids of the shelf-ready secondary packaging are transported separately in flat form between the first buildings and the second buildings,

[0022] (b) the bases and lids of the shelf-ready secondary packaging are transported in erected and assembled form carrying the primary packaging between the second buildings and the third buildings, (c) the bases and lids of the shelf-ready secondary packaging are transported in any form, preferably in flat form, from the third buildings to the first buildings;

[0023] a plurality of data exchange units distributed over the primary circuit and intended for reading the identification elements of the shelf-ready secondary packaging and transmitting the reading data;

[0024] a system control intended to control the individual shelf-ready secondary packaging in the system with their unique identification of base and lid, their respective types, and their respective positions in the system on their process paths based on the data transmitted by the data exchange units, and to control the reuse of base and / or lid based on parameters, e.g. condition, quality, degree of contamination and presence of the respective base or lid in at least the primary circuit so that in the second buildings a required number and types of bases and lids are available for the production of assembled shelf-ready secondary packaging.40261 / 4361 / PTWO 5 February 2025

[0025] 4

[0026] The primary packaging is the first level of packaging that comes into direct contact with the goods or product and encloses it. Its primary purpose is to protect the goods from external influences such as moisture, light, air, and mechanical damage. Additionally, primary packaging plays an important role in maintaining the quality and shelf life of the goods.

[0027] Shelf-ready secondary packaging is packaging specifically designed to present the primary packaging directly on the sales shelf without the need for unpacking or repacking. This type of packaging offers both practical and aesthetic benefits for retailers and consumers. These secondary packages are typically strategically placed in stores with the display side (front) facing the customer to attract attention and promote sales. They are often designed to be visually appealing and to draw customers' attention. They may include striking colors, graphics, and brand logos to highlight the products and spark customer interest. These shelf-ready secondary packages provide a structured and organized way to accept goods from the manufacturer as retail and / or to present products. The advantage of shelf ready packaging in retail is that the stocking process is optimized by placing the entire container on the shelf rather than individual items (primary packaging). This type of shelf stocking is primarily used in discount stores but is increasingly being adopted by traditional retail stores. The invention aims to standardize secondary packaging to optimally utilize shelf space in sales areas as well as transport space (modular dimensions), thereby avoiding empty volumes.

[0028] The term "primary circuit" refers to an intelligent circuit, which can also be called a "smart loop system," referring to an intelligent return system used in the distribution of goods to improve efficiency and sustainability. The inventive system offers an advanced solution that optimizes the entire logistics circuit of a shelf-ready secondary package from provisioning through product stocking to customer presentation and back. The system integrates various technologies to maximize efficiency and sustainability at every stage of the process and through the synergy of the overall system. Components of such a smart loop system can include: supply depot, manufacturer, retail and sale, re-conditioning center, and the transport mechanisms between the individual components. The various components of the40261 / 4361 / PTWO 5 February 2025

[0029] 5

[0030] system consist in reality of individual or multiple separate and spatially separated buildings, or the components are housed in different building shells.

[0031] One or more "first buildings" or building shells can include one or more supply depots and / or one or more re-conditioning centers where the inventive shelf-ready secondary packaging or their bases and lids are provided and / or at least part of the returned used bases and lids from retail are sorted, cleaned, and / or refurbished as reusable shelf-ready secondary packaging. Newly produced bases and lids can also be provided and / or labeled in the supply depot, as there can always be some inventory losses in the circuit process, for example, due to bases and lids that are no longer reusable. In the re-conditioning center, already used bases and lids can be refurbished (sorted, cleaned, and / or reconditioned). The labeling of the reusable bases and lids can also be handled by the re-conditioning center. The term "first building" is used for simplicity, even if it involves multiple first buildings and “first buildings” can also refer to only one building.

[0032] One or more "second buildings" or building shells can be the manufacturers of goods, to which the bases and lids are delivered separately from the first building in a flat state. The bases and lids are erected in the second building and filled with primary packaging containing goods. In the second building, bases and lids are assembled into the shelf-ready secondary packaging filled with primary packaging. The term "second building" is used for simplicity, even if it involves multiple second buildings and “second buildings” can also refer to only one building.

[0033] One or more "third buildings" or building shells can house supermarkets, markets, or retail in general. The erected product displays with goods are delivered from the second building to the third building by vehicles and leave the third building again in a flat, compact state without goods, as the goods are offered for sale in the third building. The term "third building" is used for simplicity, even if it involves multiple third buildings and “third buildings” can also refer to only one building.

[0034] The term "vehicles" here refers to all conventional means of transport such as cars, trucks, trains, airplanes, ships, which transport loads from one place to another. These means of transport can have suitable transport boxes that enable the transport of used product displays in a flat form from retail to the re-conditioning40261 / 4361 / PTWO 5 February 2025

[0035] 6

[0036] system. The vehicles or means of transport, as well as transport boxes, are also suitable for transporting the bases and lids prepared for reuse in the re-conditioning system to be stocked with primary packaging containing goods for retail. Transport with, for example, a forklift between a truck and a second building is also included, so a forklift, with or without a motor, is considered a vehicle.

[0037] The inventive shelf-ready secondary packaging can be brought into a flat form to save transport volume in the primary circuit with empty bases and lids. In flat form, the dead volume in the transport box is reduced. The dead volume is the volume in the transport box that is not filled by the transported bases or lids. Transport in flat form is also referred to as compressed transport. Only when they are filled with primary packaging containing goods (second building) is the intended three-dimensional form (erected form) created. This has the advantage that both during delivery and during the collection of the shelf-ready secondary packaging, a spacesaving and compressing transport box can be used as a collection container for the unfolded, empty bases and lids for the retail branch (third building) to increase transport efficiency and protect the environment. The bases and lids can have different shapes and sizes to accommodate different types of products (primary packaging), from small items like cosmetics to larger products like electronics. They can be variously foldable to make transport space- and time-saving. Providing the shelf-ready secondary packaging in a two-part form with (a) base and (b) lid allows for a clever dimensioning of the lids to reduce the number of types of bases. Also, only the non-reusable part (base or lid) needs to be sorted out, while the other part, if reusable, can continue to be used. The additional lid also allows for stacking the secondary packaging filled with primary packaging. This allows optimal use of limited space, including its vertical dimension, for providing the filled secondary packaging. The available space can be used without compromising the stability of the stacked secondary packaging and the primary packaging containing goods within them.

[0038] The plurality of data exchange units, e.g RFID readers, distributed over the primary circuit allows for asset tracking by automatically reading the identification elements, e.g. RFID transponders, and updating the data in real-time. This can be achieved by installing the data exchange units at strategic points at the primary circuit40261 / 4361 / PTWO 5 February 2025

[0039] 7

[0040] transmitting the data to a central database. By using RFID in the inventive system, automatic reordering of bases and / or lids can be enabled once the stock falls below a certain threshold, thereby avoiding out-of-stock situations.

[0041] Product displays in the state of the art are mostly made of cardboard, which is not intended for direct reuse. At best, indirect reuse is possible through a recycling step. However, many cardboard displays become unusable due to contamination, such as from food or liquids from a leaking shampoo bottle and must be disposed of directly in the residual waste. In contrast, the shelf-ready secondary packaging of the present invention meets the criteria of reusability, lightness, stability, and sustainability through the selected material (predominantly or even entirely made of corrugated plastic material) as well as the ability to attract customers' attention to highlight the products. The side walls of the base are as designable as existing product displays.

[0042] According to the principle "return is cheaper than remake," the present invention has the advantage over the existing system with cardboard or paper-based shelfready secondary packaging that it is significantly more environmentally friendly and cost-efficient. In numerical terms, the implementation of the inventive system can save 3.6 million tons of CO2, 36 million cubic meters of water, and 4 million tons of paper waste annually in Germany alone. Additionally, the present invention offers a range of individual advantages that synergize within the overall system. The invention is explained in more detail below.

[0043] The auto-identification of the bases and lids in the primary circuit (Smart Loop System) according to the invention brings various advantages. The system according to the invention integrates modem technology at least in the primary circuit to significantly improve the efficiency, accuracy, and transparency of the entire supply chain compared to the state of the art (e.g., recycling system for cardboard displays). The auto-ID technology enables real-time tracking of displays and their contents. Each display can be equipped with a unique identification element that contains information such as type and location. This allows for precise inventory management and helps avoid bottlenecks, overstock, or even theft. Various techniques for contactless reading of an identification element are known40261 / 4361 / PTWO 5 February 2025

[0044] 8

[0045] to the expert. For example, barcodes or QR codes can be read as non-rewritable optically readable codes by corresponding reading devices as data exchange units. Such identification elements can be cost-effectively applied to the shelf-ready secondary packaging but require direct sight of the reading devices on these codes for reading. In the case of RF-based identification elements such as RFID transponders or FCN transponders, these can also be read without a direct line of sight from the reading device to the identification element, but such RF-based identification elements are more expensive than barcodes, etc. Data exchange in the system according to the invention takes place between the identification element and the data exchange units distributed throughout the primary circuit as readers. The data exchange units are preferably arranged at all logistical branching points and critical process locations so that the system control can receive the data important for controlling the system to the shelf-ready secondary packaging.

[0046] In the case of an RFID transponder as the identification element, the RFID transponder consists of a microchip that stores the data and an antenna that receives and transmits the radio waves. The corresponding RFID reader as a data exchange unit consists of an antenna, a transceiver, and a decoder. Once the reader emits an electromagnetic signal, it is received by the antenna of the RFID transponder and activates the microchip in the transponder. The activated transponder then sends the stored data back to the reader via radio waves, whose antenna receives this data. The reader decodes the received data and forwards it to the system control, where it can be processed and used. The system control is connected to the data exchange units for data transmission in an appropriate manner. The corresponding data lines can be wired and / or wireless depending on the position in the primary circuit. This system control can be located in a cloud, with the cloud being part of the system according to the invention.

[0047] Various types of RFID transponders can be used: passive transponders (tags), which have no own power source and use the energy of the reader's electromagnetic field to be activated and send data; active transponders, which have their own power source (e.g., a battery) and can communicate over greater distances; and semi-passive transponders, which have a battery that powers the microchip but use the reader's electromagnetic field for communication. According40261 / 4361 / PTWO 5 February 2025

[0048] 9

[0049] to the invention, passive transponders are preferred for the displays as they have the advantage of being cost-efficient. RFID systems operate in different frequency bands: low frequency (LF) with 125-134 kHz and a short range of up to 10 cm, suitable for applications such as access control; high frequency (HF) with 13.56 MHz and a medium range of up to 1 meter, often used in libraries and for contactless payment systems; ultra-high frequency (UHF) with 860-960 MHz and a larger range of up to 12 meters, suitable for logistics and inventory tracking; and microwaves with 2.45 GHz and a very large range. RFID data exchange offers many advantages, including speed, as RFID enables fast and automatic data capture, and the advantage that no line of sight to the identification element is required, unlike barcodes, which require direct line of sight to the reader. Additionally, RFID readers can read multiple transponders simultaneously, increasing system efficiency. According to the invention, UHF RFID barcodes can be used. In addition to the RFID transponders on the bases and lids, RFID readers are installed at various points in the supply chain in the system to automatically scan and register the shelf-ready secondary packaging as they pass certain checkpoints. This reduces the need for manual scans and minimizes human errors. Especially when stacking goods in a limited space, there are significant challenges, particularly when dealing with products with a best-before date. This challenge requires careful planning and efficient use of available space to ensure that goods are properly stored and used or sold in a timely manner.

[0050] System control refers to a central element in the technical and organizational system that enables the monitoring, control, and coordination of various processes and components. It ensures the efficiency and effectiveness of the entire system by collecting, analyzing data, and making decisions based on it. The system control continuously monitors the condition and performance of the various components of the system. This can be done through sensors, cameras, or other data collection devices that provide real-time information. The collected data is analyzed and processed to assess the current state of the system. This can include anomaly detection, performance evaluation, or prediction of future states. Based on the analyzed data, the system control makes decisions and sends control commands to the various components of the system. This can include adjusting parameters,40261 / 4361 / PTWO 5 February 2025

[0051] 10

[0052] turning devices on or off, or changing operating modes. The system control coordinates the interactions between the various components of the system to ensure that they work efficiently and harmoniously together. This is particularly important in complex systems with many interdependent processes. All actions and state changes are documented by the system control. This enables traceability and helps with error diagnosis and troubleshooting.

[0053] In a circuit system for the reuse of shelf-ready secondary packaging, system control plays a central role. It monitors the shelf-ready secondary packaging transported between different buildings and ensures that they are in a suitable condition for reuse. The system control collects data on each base and lid of the shelf-ready secondary packaging, such as identification, type, position, condition, and degree of contamination. Based on this data, it decides whether a display should be reused. These decisions are documented to ensure seamless traceability. System control is thus an indispensable tool for monitoring, controlling, and coordinating processes in technical and organizational systems. It collects and analyzes data, makes decisions based on it, and documents all actions to maximize the efficiency and effectiveness of the system.

[0054] The system control also includes one or more databases, preferably a central database. This database can include, among other things, the locations of the individual bases and lids along the primary circuit. This allows a deposit system to be integrated into the system according to the invention to ensure that the displays are returned. As a basis for a deposit system, this technical system can track the position data of the bases and lids as well as their return, for example, in the first building, which makes a deposit system possible in the first place.

[0055] The system according to the invention can help reduce losses and theft by continuously monitoring the secondary packaging and thus the goods. If an item is unexpectedly moved or removed from the designated area, the system can immediately trigger an alarm and take appropriate measures. This increases security in the warehouse and protects the inventory.

[0056] The system offers seamless traceability of the secondary packaging along the entire supply chain. This means that companies always know where a particular base40261 / 4361 / PTWO 5 February 2025

[0057] 11

[0058] and / or lid is located and what its status is. This transparency is particularly important for compliance with regulations and for traceability in the event of product recalls.

[0059] The system also offers the possibility of applying any labeling or customization to the bases and lids in various ways through the appropriate choice of materials and surface structure. Compared to single-use cartons, the inventive system saves 290 grams of CO2 per use for the same content volume, according to calculations by Climate Partner.

[0060] Therefore, the task of the invention, which is to reduce the huge amount of cardboard packaging or cardboard displays and at the same time replace them with a suitable display in connection with an effective and resource-saving return and recycling system, is solved by the system according to the invention.

[0061] In an embodiment, the system is designed to exclude used bases and / or lids that cannot be reused due to damage or contamination from the primary circuit. This prevents unusable bases or lids from burdening the transport routes and potentially disrupting the loading of the shelf-ready secondary packaging with primary packaging. Preferably, the system is configured to perform this exclusion at the appropriate position in the primary circuit, for example, in the first building. The system can be configured such that each exclusion is documented by the system control. The history of exclusions can also provide insights into potential improvements in the chosen process of the primary circuit. Such data could also be important for an implemented deposit system.

[0062] In another embodiment, in the first building, which can be the processing center, a software is executed for one or more of the processes there, using machine learning and artificial intelligence through appropriate algorithms to support data analysis and process control in the sorting, cleaning, and / or preparation and provision of the shelf-ready secondary packaging, including a classification of the bases and lids according to condition, quality, and degree of contamination based on the recorded conditions, qualities, and degrees of contamination of the bases and lids, preferably the machine learning is supervised learning using classifications and / or regression This has the advantage of significantly improving the efficiency, accuracy, and sustainability of these processes. Machine learning enables the automation and40261 / 4361 / PTWO 5 February 2025

[0063] 12

[0064] optimization of control processes for the shelf-ready secondary packaging by continuously collecting and analyzing data to recognize patterns and anomalies. Based on these insights, the system can automatically make adjustments to maximize the efficiency of the shelf-ready secondary packaging, reducing the need for manual interventions and minimizing human errors. The software or parts of the software might be executed on one or more processors of a control unit arranged in the first building and connected to the system control.

[0065] Another advantage is the prediction of maintenance needs. By analyzing historical data and recognizing patterns, the software can detect signs of wear or potential failures early and schedule maintenance work in a timely manner. This prevents unplanned downtimes and extends the lifespan of the bases and lids. Additionally, machine learning can optimize the cleaning processes of bases and lids by identifying the best cleaning methods and times based on the specific requirements and degree of contamination of the bases or lids. The software can adjust the cleaning cycles to ensure that the bases and lids are thoroughly cleaned without wasting unnecessary resources, leading to more efficient use of water, cleaning agents, and energy.

[0066] Machine learning also monitors the quality of the preparation of the shelf-ready secondary packaging and ensures that all bases and lids meet the required standards. The software can analyze images and sensor data to detect errors or irregularities that may occur during preparation, allowing for quick identification and correction of problems. Furthermore, machine learning enables the software to continuously adapt to new conditions and requirements. The algorithms can learn from the collected data and improve their performance over time, leading to a continuous optimization of the control, cleaning, and preparation processes.

[0067] By optimizing the cleaning and preparation processes, machine learning contributes to resource efficiency and sustainability. The software can minimize the consumption of water, energy, and cleaning agents by precisely controlling the processes and avoiding unnecessary waste, reducing environmental impact and lowering operating costs. Machine learning can also be seamlessly integrated into existing ERP (Enterprise Resource Planning) and WMS (Warehouse Management40261 / 4361 / PTWO 5 February 2025

[0068] 13

[0069] System) systems, allowing for centralized management and analysis of all data related to the control, cleaning, and preparation of the shelf-ready secondary packaging.

[0070] The use of machine learning for the control, cleaning, and preparation of bases and lids requires carefully selected and extensive training data as well as well-defined training procedures. The necessary training data can include sensor data such as temperature, humidity, pressure, vibrations, and fill level, which helps monitoring the environmental conditions and the state of the bases and lids. Image and video data are also important to assess the quality of cleaning and detect defects or wear. Historical maintenance data, including maintenance logs and failure history, provide valuable insights into past maintenance work and its outcomes. Process data such as cleaning cycles, chemical consumption, and energy consumption, as well as operational data on the usage duration and load of the bases and lids, are also crucial.

[0071] The training procedures for machine learning begin with data preparation, where the data is cleaned, enriched, and normalized. The data is then split into training, validation, and test datasets. Model training involves selecting appropriate ML algorithms (e.g., decision trees, neural networks, support vector machines), hyperparameter tuning, and cross-validation (k-fold cross-validation) to ensure the robustness of the model. Model evaluation is performed using performance metrics such as accuracy, precision, recall, F1 -score, and ROC-AUC, as well as error analysis to identify areas for improvement. After training, the model is integrated into the real-time system and continuously monitored and maintained.

[0072] The required amount of data for visual inspection and error detection can include thousands to tens of thousands of images or videos to train a robust model. The data split can be as follows:

[0073] Training data 70% -80%: the majority of the data is used fortraining the model. This data is used to learn the model parameters and recognize the underlying patterns in the data.

[0074] Validation data 10% - 15%: a portion of the data is used for validation. This data helps optimize the model's hyperparameters and monitor performance40261 / 4361 / PTWO 5 February 2025

[0075] 14

[0076] during training. The validation data is not used fortraining the model but serves to evaluate the model's generalization ability and avoid overfitting.

[0077] Test data 10% - 15%: a separate portion of the data is used for the final evaluation of the model. This data is used only after training and hyperparameter optimization to measure the model's final performance. The test data provides an objective assessment of the model's generalization ability on unknown data.

[0078] An example of the dataset structure could be as follows:

[0079]

[0080] Here, the following data is measured and included as a dataset:

[0081] • Identification Element ID: Unique identification number of the bases and lids (base-ID or lid-ID).

[0082] • Temperature (°C): Measured temperature in the bases and lids.

[0083] • Humidity (%): Measured humidity of the bases and lids.

[0084] • Vibration (Hz): Measured vibrations of the bases and lids.

[0085] • Cleaning Cycle (min): Duration of the cleaning cycle in minutes.

[0086] • Chemical Consumption (ml): Amount of cleaning agents used in milliliters.

[0087] • Energy Consumption (kWh): Energy consumption during the cleaning cycle in kilowatt-hours.

[0088] • Maintenance Date: Date of the last maintenance of the bases and lids.

[0089] • Image URL: URL to an image of the bases and lids for visual inspection.

[0090] • Quality Rating: Assessment of the quality of the bases and lids after cleaning (e.g., Good, Very Good, Satisfactory).

[0091] In another embodiment, the Al can learn based on boundary patterns. The use of machine learning for sorting contaminated bases and lids based on boundary40261 / 4361 / PTWO 5 February 2025

[0092] 15

[0093] patterns also requires careful planning and execution. First, image data of bases and lids in various states of contamination must be collected. These images should be taken from different angles and under different lighting conditions. The images need to be manually annotated by marking the contaminated areas and classifying the types and severity of contamination. After data cleaning and augmentation, the data is split into training, validation, and test datasets.

[0094] For the model architecture, a suitable model for image processing and object detection is selected, such as Convolutional Neural Networks (CNNs) or specialized models like YOLO (You Only Look Once) or Faster R-CNN. The model architecture is adapted to the specific requirements of the task. Training the model involves hyperparameter tuning, the training process with techniques like backpropagation and Stochastic Gradient Descent (SGD), and validation with the validation dataset. Model evaluation is performed using performance metrics and error analysis.

[0095] After training, the model is integrated into the real-time system for sorting contaminated bases and lids. Continuous monitoring and maintenance of the model ensure that performance remains high in real-time operation. An example of a training dataset could include the following fields: Image ID, Image URL, Type of Contamination, Severity, and Bounding Box (x1, y1, x2, y2). The data and software can be stored and processed in the cloud.

[0096]

[0097] Another application of Al is the more precise forecasting of demand for the new production of reusable secondary packaging. The variety of different users of the secondary packaging, their diverse processes and conditions, and uncontrollable additional factors such as weather, result in traditional forecasting methods providing only inadequate results regarding the expected return of secondary40261 / 4361 / PTWO 5 February 2025

[0098] 16

[0099] packaging within specific time periods. To avoid resource-wasting overstock or holding costs, Al is used to determine the optimal forecasting model for each subarea based on the product, secondary packaging type, and customer structure. By aggregating the individual results, a significantly better overall outcome can be achieved.

[0100] In another embodiment, the sorting of the returned shelf-ready secondary packaging is carried out in a sorting unit configured to perform a sensor-based incoming inspection for the bases and lids and to exclude the base and / or lid, which has been classified as non-reusable due to condition, quality, and degree of contamination, from the primary circuit. Thus, process effort can be restricted to bases and lids, which can be reused improving the process efficiency.

[0101] In another embodiment, the sorting comprises at least first sensors, preferably an RFID reader, for reading the identification element, preferably an RFID transponder, of the base and / or lid of the shelf-ready secondary packaging to determine and classify the respective type of base and lid, and at least second sensors for recording the condition and / or quality and / or degree of contamination of the base or lid in order to carry out the incoming inspection. By precisely determining and classifying the bases and lids using the first sensors, which identify the type of base or lid, correct assignment and treatment of each base and lid is ensured. The integrated RFID reader reads the RFID transponders of the bases and lids, enabling quick and reliable identification, as the transponders contain specific information that can be captured automatically and without manual intervention. Additionally, second sensors assess the condition and quality of the bases and lids. This automatic assessment is crucial to ensure that only bases and lids in good condition are reused or sold. Early detection and sorting out of defective or damaged bases and lids improve the overall quality of the products. The sensors detect the degree of contamination of the display stands, which is particularly important in industries where hygiene and cleanliness play a significant role, such as the food or pharmaceutical industry. Based on the data from these sensors, bases and lids that require cleaning can be automatically identified and treated accordingly. The integration of these sensors into the sorting unit allows for extensive automation of the sorting process, reducing manual effort and minimizing human errors. The40261 / 4361 / PTWO 5 February 2025

[0102] 17

[0103] automated capture and classification of the bases and lids accelerate the sorting process, leading to a higher throughput rate. The second sensors can be optical sensors connected to an evaluation unit, on which recognition software for detecting and classifying the condition, quality, and degree of contamination of the respective base or lid is executed, with the recognition software using artificial intelligence through appropriate machine learning algorithms. Optical sensors have the ability to perform precise and contactless measurements with fast response time and high spatial resolution advantageous in a fully automated processing plant. They are insensitive to electromagnetic interference making them ideal for use in industrial environments where electromagnetic fields are common. Furthermore, optical sensors can operate reliably in extreme temperature ranges and under challenging conditions such as dust, moisture, or vibrations.

[0104] The sorting unit might be configured to record parameters relating to condition, quality, and degree of contamination on both sides of the base and lids, which are fully spread out in one plane. The detection substrate, where the bases and lids are placed to measure the parameters, might be transparent to enable simultaneous determination of condition, quality, and degree of contamination on both sides of the base and lids This measure increases speed and accuracy of the classification and ensures that no defects or contaminations are overlooked, leading to improved quality assurance and time efficiency in the sorting process.

[0105] In another embodiment, the sorting unit comprises a plurality of collection containers and one or more sorting means, preferably gripping robots, which are designed to enable a type-based sorting of the respective bases and lids into collection containers based on parameters e.g. the classified condition, quality, and degree of contamination of the respective base or lid, with each collection container being assigned to different types and classifications of e.g. condition, quality, and degree of contamination. The gripping means can be designed differently. For example, gripping robots enable precise sorting of the bases and lids into collection containers, each assigned to the different classifications of condition, quality, and degree of contamination. Type-based means that only a specific type of base or lid is sorted into each collection container. Therefore, an appropriate number of collection containers is arranged around the sorting means. The automated and classified40261 / 4361 / PTWO 5 February 2025

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[0107] condition-based sorting significantly increases the efficiency of the sorting process. This leads to a reduction in manual interventions and minimizes human errors, resulting in improved quality assurance and optimized management of the primary circuit. The sorting containers may comprise one or more additional containers for receiving with bases or lids of all classifications as a temporary buffer container for full and exchangeable collection containers for specific classifications, and / or for providing an intermediate storage for bases or lids with incorrect spatial orientation. Buffer containers allow for efficient use of space, as full and exchangeable collection containers for specific classifications can be temporarily stored. This prevents bottlenecks in the sorting process and ensures smoother handling. The arrangement of the collection containers and the possibility of intermediate storage of bases and lids with incorrect spatial orientation contribute to optimizing the material flow. This leads to smoother and more efficient processing of the bases and lids. Finally, the provision of additional collection containers (second and third collection containers) increases the overall capacity of the system, enabling the handling of larger quantities of bases and lids and improving the scalability of the system. The bases and lids may be supplied to the sorting means for sorting either continuously by suitable conveying means or in batches by means of input containers from an entry point in the first building, The transport boxes may serve as input containers.

[0108] In another embodiment the sorting unit comprises a pre-sorting station designed to separate the used bases and lids in the received transport boxes from other contents in the transport boxes by means of appropriate classification of the content by the sorting unit using suitable sensors for recognizing the content, preferably the other content in the sorting unit are fed to a separate further use or disposal outside the primary circuit. It may happen that when filling the transport boxes at the retail (in the third building) for return transport to the first building, additional content is intentionally or mistakenly placed in the transport boxes that is not reusable shelfready secondary packaging. For example, these are ordinary cardboard or paper displays for which no reuse is intended. Furthermore, the additional content can be, for example, outer packaging, etc. This additional content can be intentionally present in the transport boxes, provided that the inventive system offers40261 / 4361 / PTWO 5 February 2025

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[0110] disposal / recycling of the additional content, such as non-reusable cardboard or paper displays, in addition to the processing of reusable bases and lids of the shelfready secondary packaging. The inventive system is therefore also capable of performing such separating pre-sorting through pattern recognition of the sorting software. The inventive system can thus also be extended to such additional tasks by training the sorting recognition software for such scenarios and performing such classifications during application to automatically control and execute the sorting out and removal of the sorted-out additional contents of the transport boxes. The presorting station might be integrated into the incoming inspection of the sorting unit.

[0111] In another embodiment, the first building comprises a cleaning unit which is intended to clean and / or process the bases and lids handed over by the sorting unit, for which purpose the cleaning unit comprises one or more cleaning lines with respective processing stations arranged in series. This ensures that the bases and lids are brought to a hygienically impeccable condition, which is particularly important in industries such as food or pharmaceuticals. By integrating the cleaning unit into the processing system, the entire process of cleaning and disinfection is automated and efficiently designed, leading to improved quality assurance and a reduction in manual cleaning efforts. The sequentially arranged processing stations enable continuous and efficient cleaning and disinfection of the bases and lids, as they are automatically transported through the various processing stations. This results in uniform and thorough cleaning, reduces manual effort, and increases productivity. Different cleaning lines can be tailored to specific types and / or uses of bases and lids to optimize the cleaning process individually for the display stand type. The number of processing stations per cleaning line depends on the planned process. For example, one cleaning line could include first, second, and fifth processing stations. Another cleaning line could include first, second, third, and fifth processing stations. Another cleaning line could additionally include fifth and / or sixth processing stations. Depending on the applied process, a different number of processing stations could be present in the respective cleaning line. Different cleaning lines can include different numbers of processing stations. The processing stations may be one or more of a first, a second, a third, a fourth and / or a fifth processing station, where the terms “first”, “second”, “third”, “fourth”, “fifth” etc. only denotes the40261 / 4361 / PTWO 5 February 2025

[0112] 20

[0113] processing stations to distinguish a particular processing station from other processing stations und does not prescribe a specific sequence in the arrangement of the processing stations in a cleaning line of the cleaning unit. In some embodiments there might be even more processing stations as part of the cleaning unit. The individual cleaning lines and their processing stations might be specifically intended either only for bases or only for lids for their cleaning and / or processing. Since bases and lids differ solely in their geometric shape, a cleaning line adapted solely to bases or lids allows for better cleaning results.

[0114] In another embodiment, the multiple processing stations (32a-f) are one or more processing stations of

[0115] a first of the processing stations (de-labeling station) to detect and remove labels at least on the bases;

[0116] a second of the processing stations (cleaning station) carrying out the cleaning process of the base and / or the lid by means of wet cleaning and / or by means of dry cleaning;

[0117] a third of the processing stations (drying station) drying the bases and lids cleaned with the preceding wet cleaning;

[0118] a fourth of the processing stations (disinfecting station) for disinfecting the bases and / or lids arranged the second or third processing station;

[0119] a fifth of the processing stations (labeling station) for labeling at least the bases after cleaning or disinfection, wherein at least one base label is applied to one side wall of the base, and / or a presentation label or removable cover in the form of the display side is applied or connected to the display side, both on top of a prepared application surface

[0120] The de-labeling station ensures that unnecessary and disruptive labels for the reuse process are removed. This improves the efficiency and quality of the cleaning process by avoiding potential contamination from label residues. De-labeling is an important part of the primary circuit for the "re-conditioning" of display stands. The removal of labels can preferably be carried out by blowing them off, provided the labels and / or the base are prepared for this. For example, the adhesive layer of the label can be omitted in the edge area of the label, so that the edge of the label slightly protrudes, where compressed air can attack to blow the label away. The40261 / 4361 / PTWO 5 February 2025

[0121] 21

[0122] alignment of the blowing device is predetermined by the known orientation and shape of the base in this processing station. The cleaning station allows for thorough and flexible cleaning, tailored to the specific requirements of the bases and lids, e.g. wet cleaning with applying a cleaning fluid or dry cleaning e.g. by blowing of or brushing the bases and lids. The drying station ensures that the cleaned bases and lids are dried after wet cleaning, for example, using a gas blower, thermal radiation, or a spinning process. This ensures that the display stands are completely dry and ready for use after cleaning, increasing the efficiency and quality of the entire cleaning process. The drying process prevents, for example, the sticking together of bases or lids stacked on top of each other in transport boxes due to remaining residual moisture. The disinfecting station (e.g. by UV irradiation) ensures effective and thorough disinfection, which is particularly important for maintaining high hygiene standards. The arrangement of the disinfection station along the conveyor belt behind the processing station for drying is particularly advantageous. This placement ensures that the bases and lids are immediately disinfected after drying, thereby increasing the efficiency and quality of the entire cleaning and disinfection process. The applied base label provides a surface for the operators of the second buildings to further apply specific information about the primary packaging (such as type of goods, manufacturing date, place of manufacture, etc.) that are packed into the bases in the second buildings, onto the base label. For this purpose the base label is a blank label not restricting the operators of the second buildings in terms of the application technique to attach the specific information onto the base label. The goods packer can further stick (with the goods packer's over-label in the second building) or print on the existing base label on the base, but the sticking or printing must not go beyond the area of the base label to ensure that the base label can still be easily removed in the first building. In addition to the base label, also a presentation label in the form of the display side might be applied onto the display side of the base. A "presentation label" is understood to mean a marking that is used as a flexible decoration principle to enable advertising and attention generation for the primary packaging in the third building towards the customer. In order to be easily removable in the de-labeling station, the base label and / or the presentation may each comprise at least one lateral side area not adhere to the base or the application surface of the base, or comprises a pull tab to prepare for the successful40261 / 4361 / PTWO 5 February 2025

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[0124] removal of the base label and / or the presentation label during reuse of the respective base in the first of the processing. Alternatively to the representation label, a removable cover might be connected of the display side, preferably the fixing means of the display side is realized as one or more suitably dimensioned slots and the corresponding fastening means of the cover is realized as one or more suitably shaped tabs. The cover serves the same purpose as the presentation label. The bases and lids may pass through the respective cleaning line on a conveyor belt such a way that they lie completely spread out on the conveyor belt or hang on the conveyor belt. When the cover is used, no additional label is required. Instead, the cover (either single-use or reusable) is inserted by a robot after cleaning, thereby branding the standard secondary packaging. When the secondary packaging is returned from the retail store (third building) to the reconditioning center, the panel is then removed by a robot. In the case of a single-use cover, it is disposed of, while in the case of a reusable cover, it is stored by type.

[0125] In another embodiment, the cleaning unit is set up to carry out a sensor-based final inspection of the respective bases and lids after passing through the cleaning unit and to classify them regarding condition, quality, and degree of contamination, and to exclude the bases and lids classified as non-reusable from the primary circuit. This ensures that only bases and lids in perfect condition are reused, which increases the quality and efficiency of the entire primary circuit process. The ongoing results of the final inspection can be fed back into the self-learning process control as feedback data, which continuously improves the process success.

[0126] In another embodiment, the first building comprises a packing unit for type-based sorting and packaging of bases and lids, which have passed the cleaning lines, in separate transport boxes each comprise a bottom of the box and side walls of the box around the bottom of the box, where the bases and lids are packed as individual stacks by folding or flapping the bases or the lids in a flat state into one or more compartments of the transport box, to provide reusable shelf-ready secondary packaging for further use. This packing unit ensures that the cleaned and disinfected bases and lids are efficiently sorted and provided for reuse. This optimizes the entire process by enabling seamless integration of cleaning and sorting, thereby increasing efficiency and productivity. By positioning the bases and lids specifically40261 / 4361 / PTWO 5 February 2025

[0127] 23

[0128] on the transport means, handling and distribution are facilitated, leading to increased efficiency and productivity. The packing unit may use conveyor belts and / or placement robots for sorting and packaging the bases and lids. The sorting can be analogous to the sorting in the sorting unit.

[0129] In another embodiment, the packing unit is intended to perform one or more of the following processes (a) to insert one or more partition walls (61c) into the transport box to divide the transport box into several suitable compartments within the walls of the transport box, (b) to close the transport box with a cover lid, and (c) to store data for the unique identification of the bases and lids transported with the transport box in a machine-readable data storage (62) of the transport box. Insertable partition walls allow flexible design of different compartments. Here, the transport boxes could be retrofitted to the respective need for transporting bases or lids. Also, a folded transport of empty transport boxes is facilitated if partition walls can be removed before empty transport to facilitate flat laying of the transport box for volume-reduced transport. These are then reinserted into the erected transport boxes in the packing unit. The cover lids protect the stacked bases and lids inside the transport box from getting dirt during the transport. The stored data allows the transport of bases and lids from the first to the second building to be effectively monitored and the provision of the required number of bases and lids to be precisely controlled, as the position and content of the transport boxes can be matched and tracked with the target values.

[0130] In another embodiment, the system further comprises a secondary circuit logistically linked to the primary circuit in the one or more first buildings to transfer excluded bases and lids from the primary circuit to the secondary circuit and newly manufactured bases and lids back to the primary circuit, and a recycling unit to granulate the excluded non-reusable bases and / or lids and to manufacture the new bases and lids from the granulate or to supply them for other use. The secondary circuit ensures that non-reusable bases and lids are also efficiently and environmentally friendly recycled to enable the sustainability of the entire system. The secondary circuit can also be called the "Smart Recycling System," which can meet the primary circuit "Smart Loops System" at various touchpoints. Components of the secondary circuit can be buildings or building shells for production, granulation,40261 / 4361 / PTWO 5 February 2025

[0131] 24

[0132] supply storage, and newly manufactured bases and lids. The inventive system can include a fourth building for production, a fifth building for granulation, and a sixth building for supply storage. The first building as a processing system is well suited as a link point for feeding the new bases and lids into the primary circuit. This feeding can be done by delivery to the entrance area of the first building with subsequent sorting and cleaning.

[0133] In another embodiment the recycling unit is designed to equip the new bases and lids with the identification elements, wherein the date of new manufacture, preferably also the date of first use of the original material, is stored in the identification element by means of data exchange units distributed over the secondary circuit. Thus, precise traceability and management of the bases and lids can be ensured from the time of manufacture to increase reliability and transparency throughout the system, including the secondary circuit. The identification elements can be glued to the bases and lids from the outside, for example. Alternatively, these can be embedded in the material of the bases and lids during the manufacturing process of the bases and lids.

[0134] In one embodiment of the inventive system, the shelf-ready secondary packaging is a talking box, in which a NFC or HF RFID chip is particularly attached to the base, from which information on the goods can be read out by a customer. In particular, the information can be input by an entity of the second or third building, where the manufacturer or the retailer resides to input information for customers to be transported to the point of sale. Customers can read out the information from e.g. their smartphone when standing close to the secondary packaging. The talking box allows advantages as barrier-free shopping, freshness control, product navigators etc.

[0135] The invention further relates to a shelf-ready secondary packaging for use in the inventive system, wherein the shelf-ready secondary packaging is designed in two parts comprising a one-piece foldable base at least consisting of a bottom and several side walls surrounding the bottom with a display side as well as a separate one-piece foldable lid, wherein the lid and base can be reversibly converted multiple times from a flat state to an erected form and back by folding along pre-fabricated40261 / 4361 / PTWO 5 February 2025

[0136] 25

[0137] fold lines, wherein the erected form of the base is intended for filling with primary packaging containing goods, wherein both base and lid consist of more than 50% by weight of a corrugated plastic material, wherein the lid is intended to be joined with the base in a suitable form to enclose the primary packaging as a filled shelfready secondary packaging together with the filled base at least during transport, wherein the base and lid each comprise at least one identification element for the unique identification of at least the types of base and lid and to determine their positions in the system, preferably the identification element is connected to or integrated into the base or lid at a suitable position.

[0138] The term "corrugated material" refers to a type of structured material, here plastic material, that consists of a fluted or ridged layer sandwiched between two flat linerboards. The ridged layer may comprise vertical webs between the linerboards. This design creates a series of parallel ridges and grooves, which significantly enhances the material's strength and rigidity while keeping it lightweight. The fluted layer provides cushioning and protection for the contents inside. The versatility and cost-effectiveness of corrugated materials make them an advantageous choice for the base and lid of the shelf-ready secondary packaging. The plastic material can be at least partially, preferably completely, made from a synthetic or semi-synthetic polymer, preferably polypropylene, a bio-based polymer, a sugar-based plastic, preferably from ethanol, or a combination thereof. Bases and lids, as structures made predominantly from material and plastic as the material for the corrugated structure, offer specific advantages in terms of stability, weight, and material savings, allowing the shelf-ready secondary packaging to meet various requirements. Due to the material used, the shelf-ready secondary packaging is designed to remain stable and securely hold the goods even when exposed to moisture or mechanical stress. This minimizes the risk of damage or loss of goods.

[0139] The two-part design is due to different logistics routes and processes within / between buildings. Since the shelf-ready secondary packaging is only assembled from the base and lid in the second building to protectively enclose the primary packaging and the primary packaging is offered to customers in the third buildings in the bases without lids, a two-part design of the shelf-ready secondary packaging is required. However, due to reusability, all bases and lids return to the first buildings and must40261 / 4361 / PTWO 5 February 2025

[0140] 26

[0141] be logistically delivered in parallel to the second buildings without being transported together.

[0142] In the flat form, parts of the base and lid are folded onto respective base areas of the bases or lids, so that the base and lid are preferably folded into a flat form made of two layers of material. The flat form thus essentially corresponds to a two-dimensional shape, although the flat form naturally also has a thickness (3rd dimension) due to the material thickness of the corrugated plastic material, but the thickness is significantly smaller than the length and width of the flat form of the base and lid. Depending on the arrangement of the fold lines in the base and lid, the base area may differ from the bottom area of the base or the lid area of the lid. In the erected form, the base and lid have the intended three-dimensional shape for receiving and covering the primary packaging filled with goods.

[0143] The fold edges (also referred to as fold lines) are located at suitable edges or lines between the bottom, side walls, and lid surface or within these surfaces as edge- or surface-long material thinnings for folding the base and lid. This construction offers high flexibility and facilitates the assembly and handling of the product display. A base or lid running through fold edges is still firmly connected and thus each a one-piece base or lid.

[0144] Due to the lid, the secondary packaging filled with primary packaging becomes stackable, which would not be the case with secondary packaging without a lid. The lid is therefore essential for space-saving transport of the primary packaging (stackability) while ensuring protection of the primary packaging in the shelf-ready secondary packaging from transport damage from the second to the third building. The assembly of the base and lid can be done in any suitable way, for example by inserting parts of the lid into parts of the base or by appropriately placing these parts together.

[0145] In retail stores, the inventive secondary packaging can be folded directly at the sales shelf, saving frequent trips from the sales shelf to the store's storage area or compactor with erected glued cartons, resulting in time optimization. Also, the inventive shelf-ready secondary packaging allows for easy, space-saving manual40261 / 4361 / PTWO 5 February 2025

[0146] 27

[0147] folding of the box without additional tools in retail stores. This reduces the risk of accidents, as single-use cardboard cartons are often cut with utility knives.

[0148] The inventive shelf-ready secondary packaging must be recognizable for system control in the system. For this purpose, both the base and the lid include at least one identification element for uniquely identifying their types and determining their positions in the system by recognizing and reading the identification elements with the data exchange units. "Identification element" can refer to any auto-ID technology. These technologies serve the automatic capture and processing of data without human intervention. In addition to pure recognition identification elements like barcodes or QR codes, electronically writable identification elements such as RFID chips (Radio Frequency Identification) can also be used, enabling contactless tracking of objects. Possible alternatives include NFCs, BLE, UWBs, Wi-Fi, GPSbased identification elements. It is also possible to apply different technologies for bases and lids. Implementing an identification element on the base or lid is relatively simple and cost-effective. The identification element can either be glued to the surface of the base or lid at a suitable position or, in the case of RF-readable identification elements, integrated into the material of the base or lid. Modern RF transponders are robust and resistant to environmental influences, thus also to the cleaning processes for reuse.

[0149] Therefore, the task of the invention, which is to reduce the huge amount of cardboard packaging or cardboard displays through a suitable display (shelf-ready secondary packaging) in connection with an effective and resource-saving return and recycling system, is solved by the shelf-ready secondary packaging.

[0150] In one embodiment, the identification element is designed to be digitally written with data, preferably the identification element is a RF-tag, which can be written to and read from using RF technology. This is advantageous because the identification element does not need to be replaced for each reuse cycle. It remains with the respective base or lid and is described with new data such as the processes carried out in the first building as needed. As described above for the system, data exchange in an RFID system occurs between an RFID chip, here the identification element (also called a transponder), and an RFID reader, here the data exchange40261 / 4361 / PTWO 5 February 2025

[0151] 28

[0152] units in the inventive system (also called a reader). Various types of RFID transponders can be used: (a) passive transponders, which have no own power source and use the energy of the reader's electromagnetic field to be activated and send data, and (b) active transponders, which have their own power source (e.g., a battery) and can communicate over greater distances. According to the invention, passive transponders are preferred as identification elements for the bases and lids of the shelf-ready secondary packaging because they are more cost-efficient and do not require a battery, thus not needing to be recharged. RFID technology can be seamlessly integrated into existing ERP (Enterprise Resource Planning) and WMS (Warehouse Management System) systems. This enables centralized management and analysis of all inventory data, leading to better decision-making processes and optimized inventory management. Companies can monitor inventory data in realtime and make informed decisions to improve inventory management. By integrating the content (goods) with the unique identification element of the shelf-ready secondary packaging, information about the goods can be associated with the shelfready secondary packaging. Additionally, events affecting the goods during distribution can be recorded on the identification element.

[0153] In another embodiment, the lid comprises at least two support side walls foldably connected to a lid surface to be inserted between the primary packaging and the corresponding opposite side walls of the erected and filled base along the side walls of the base when joined with the base, where the support side walls have a suitable height rest on the bottom of the base, preferably the lid surface is completely surrounded by foldable side walls. For foldability, appropriate fold lines are arranged between the support side walls (and possibly other side walls of the lid) and the lid surface. The lid surface covers the primary packaging present in the base from above and is therefore advantageously a flat surface. The thickness of the lid surface is chosen to be sufficiently thick to ensure the stackability of the shelf-ready secondary packaging. Here, the support side walls significantly support the stackability by standing approximately at a right angle to the lid surface and being inserted into the base, thus supporting the lid surface resting on the bottom of the base. By inserting the support side walls of the lid only between the primary packaging and the side walls of the bottom, the primary packaging and the side40261 / 4361 / PTWO 5 February 2025

[0154] 29

[0155] walls of the base also support the support side walls in their task of supporting the lid surface. Therefore, relatively thin side walls can be used for the lid and base, as they work together in their functions. Preferably, the lid surface is surrounded by foldable side walls. The lid does not require any components to be mechanically connected to corresponding components of the base. Base and lid is only connected by inserting the support walls of the lids between the primary packaging present in the base and the side walls of the base. Therefore, any lid will fit to any base with corresponding width and length. The lid is therefore not placed on the base like a cover, but is pushed into the base with the support side walls.

[0156] In another embodiment, different types of lids are provided for different heights of primary packaging, wherein the heights of the two opposite support side walls of the respective lid type are adapted to the respective height of the primary packaging. This allows the same base to be used for primary packaging of different heights, to enclose the primary packaging for transport together with the side walls of different lids adapted to the height of the primary packaging. There may be a gap between the upper edge of the side walls of the base and the lid surface of the lid on the sides where the lid does not include side walls. However, this gap does not affect the stackability of the shelf-ready secondary packaging in the filled state with primary packaging, as at least the two inserted side walls of the lid ensure sufficient stability for the lid surface in conjunction with the primary packaging present below the lid surface. This leads to a reduced number of types needed for the base, thereby increasing system integration and facilitating the provision of the required bases in the second building through the associated reduced logistics complexity.

[0157] In another embodiment the base comprises an application surface on at least one of the side surfaces for applying a base label thereon, which specifically reduces the adhesion of the base label on the application surface to achieve sufficient adhesion of the base label during a cycle in the primary circuit and to enable easy removal of the base label in the cleaning unit by blowing off. The application surface represents the substrate for the base label to be applied and can be adapted and coordinated to the process requirements in the cleaning line (removal of the base label) and in the other primary circuit (sufficient adhesion of the base label on the application surface). Thus, a specific adhesion provided by the application surface in40261 / 4361 / PTWO 5 February 2025

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[0159] conjunction with the adhesive side of the base label can fulfill both requirements. Preferably, the surface on which the application surface is located is the side surface opposite the display surface. Since the operators of the second buildings apply product information such as batch numbers, packing dates, etc. to the base label, this information is less important to the customer and can therefore be located on the back of the shelf-ready secondary packaging on the customer shelf. The application surface 'may completely cover the side surface opposite the display surface. This offers the entire side surface as an application location for applying the base label, thus enabling a flexible labeling process with a large process window, which can also take into account technical requirements and restrictions in the second buildings during the application of information.

[0160] In another embodiment, the application surface is provided by a silicone coating of the side surface or by a permanently remaining silicone-coated base label on the side surface. Such a silicone coating or silicone layer / surface allows precise adjustment of the adhesion properties between the application surface and the base label.

[0161] In another embodiment, the application surface is also present on the display surface for the reversible application of a presentation label, preferably completely covering the display side. The display surface is the front side of the base facing the customer on the shelf in the third buildings. Thus, the goods in the primary packaging can be additionally advertised through the design of the display side, separate from the designs on the primary packaging. The technical enablement of this design request is achieved by the application surface also on the display side. The same statements apply to the application surface on the display side as previously mentioned for the substrate of the base label.

[0162] In another embodiment the base comprises a reversibly attachable and removable cover that can be placed on the display side from the outside, wherein the display side comprises fastening means, preferably one or more suitably dimensioned slots, which interact with corresponding fastening means of the cover, preferably one or more suitably shaped tabs, to fix them together. This construction allows for easy and secure attachment of the cover to the product display, increasing the flexibility40261 / 4361 / PTWO 5 February 2025

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[0164] and adaptability of the product display. The cover can be a disposable part that is assigned to a manufacturer of the primary packaging by printing or labeling and can be placed on the base in the first or second building to advertise the primary packaging. When using a cover, the display side does not need to be provided with an application surface. The cover can be made of the same corrugated material as the base and lid. The cover can also be one-way or reusable.

[0165] In one embodiment, the shelf-ready secondary packaging is a talking box, in which a NFC or HF RFID chip is particularly attached to the base, from which information on the goods can be read out by a customer, in particular, the information can be input by an entity of the second or third building. The advantage hereby are the same as described in the parallel embodiment of the inventive system, where information of the goods within the shelf-ready secondary packaging is made available for the user. e.g. the customer. Especially NFC (Near Field Communication) is a wireless communication technology that allows data exchange over short distances. By attaching an NFC transponder, users can quickly and easily access important information about the shelf-ready secondary packaging by holding their NFC-enabled device near the transponder. This makes the shelf-ready secondary packaging a "talking box" that "speaks" to the user on demand, i.e., exchanges data. The information for the talking box can, for example, be loaded onto the NFC transponder as an identification element of the product display by the operator of the second or third building.

[0166] The invention further relates to a transport box with at least one stack of a plurality of bases or lids of the shelf-ready secondary packaging each in flat form according to any of the inventive secondary packaging for transporting either the base or the lid at least in a primary circuit by means of vehicles between first and second and / or third and first buildings in the primary circuit, wherein the transport box comprises a bottom of the box and a side wall of the box surrounding the bottom of the box defining at least one compartment for receiving the stacked bases or lids, wherein the compartment is adapted in width and / or length to the bases and lids in flat form so that they are tightly enclosed on at least two sides. The transport box can be made of any robust material suitable for shipping packed contents. The bottom of the box might be made from a hard plastic material to withstand the stresses of40261 / 4361 / PTWO 5 February 2025

[0167] 32

[0168] vehicle transport and storage transport. The side walls surrounding the bottom can be made of the same or a different material, for example, cardboard or plastic material. The surrounding walls can be made in one piece from interconnected walls, the edges of which are foldable to be able to store the side wall of the box in a flat form. The foldability of the surrounding walls allows for space-saving return transport of the transport boxes in an empty state to a location in the primary circuit where transport volume is needed. The compartment of the transport box refers to a surface on or parallel to the bottom of the transport box within the transport box, on which the bases or lids can be placed in a flat form, with the compartment holding the bases or lids slip-resistant on at least two opposite sides. The lateral enclosure of the flat-laid bases and lids increases their stability during transport, minimizing damage and facilitating handling.

[0169] In one embodiment, the transport box comprises one or more insertable partition walls with which several suitable compartments can be separated within the same transport box. The insertable partition walls allow for quick adjustment of the dimensions of the compartments when other or more compartments are needed. For example, a transport box that has just transported lids could be converted to transport bases, as the flat bases and lids may have different surface areas. The insertable partition can, for example, be inserted into pre-made grooves in the surrounding wall of the transport box. These grooves can be symmetrically present on opposite wall passages on the inside of the surrounding wall of the transport box to divide the transport box in one direction with the partition. Alternatively, the partition can also run through only part of the interior surface of the transport box and is therefore only inserted into one side of the surrounding wall of the transport box.

[0170] In another embodiment, the transport box comprises a machine-readable data storage, in which data for the unique identification of the bases and lids transported with the transport box can be stored. This enables precise and efficient traceability of the bases and lids of the shelf-ready secondary packaging during transport. By storing and retrieving specific data, the management and control of the shelf-ready secondary packaging is improved, leading to the optimization of logistics processes in the inventive system.40261 / 4361 / PTWO 5 February 2025

[0171] 33

[0172] The bottom of the transport box can have a surrounding groove or ledge so that the surrounding walls can be inserted into the groove or onto the ledge in one piece, thus providing the transport box reversibly with little effort.

[0173] In another embodiment, the transport box has a cover lid to be placed onto the side wall from above, so that the transport volume of the transport box can be closed laterally by the walls, downwards by the bottom, and upwards by the cover lid. The lid can be made of the same material as the walls. The transport boxes can be made of contamination-resistant material and closed by a similarly resistant cover lid. This ensures the cleaned and disinfected state of the bases and lids even at later points in the transport in the primary circuit.

[0174] Thus, the object of the invention, which is to reduce the huge amount of cardboard packaging or cardboard displays through a suitable transport box for transporting the bases or lids of the shelf-ready secondary packaging in conjunction with an effective and resource-saving return and recycling system, is achieved by the transport box according to the invention.

[0175] The invention further relates to a method for operating an inventive system with at least one primary circuit for the reuse of two-part shelf-ready secondary packaging made of separate joinable bases and lids, which include at least one identification element for uniquely identifying at least the types of base and lid and for determining their positions in the system for the appropriate presentation and delivery of goods, wherein the primary circuit extends over a plurality of separate and spatially separated buildings, the method comprising the following steps:

[0176] Automatic processing by sorting, cleaning and / or reconditioning the bases and lids returned from the second or third buildings in the first buildings in separate processes for bases and lids and providing at least a part of the returned bases and lids as reusable shelf-ready secondary packaging;

[0177] Transporting the bases and lids of the shelf-ready secondary packaging in a flat form separately to the second buildings by one or more vehicles;

[0178] Erecting and filling the bases in the second buildings with primary packaging and joining the bases and lids to form shelf-ready secondary packaging filled with primary packaging;40261 / 4361 / PTWO 5 February 2025

[0179] 34

[0180] Transporting the erected shelf-ready secondary packaging in a stacked state from the second buildings to the third buildings by one or more vehicles;

[0181] Receiving the shelf-ready secondary packaging filled with primary packaging in the third buildings and removing the lids from the respective bases to offer the primary packaging in the bases;

[0182] Returning used bases and lids in a flat form or another state from one or more second or third buildings to one or more first buildings by one or more vehicles; Controlling the system by means of a system control using a plurality of data exchange units distributed over the primary circuit for reading the identification elements of the shelf-ready secondary packaging and for transmitting data from the reading, which are suitably connected to the system control, wherein the system control is intended to control the individual shelf-ready secondary packaging in the system with their unique identification of base and lid, their respective types, and their respective positions in the system on their process paths and, based on the knowledge of the data for each base and lid of the shelf-ready secondary packaging at least along the primary circuit, to control the reuse of base and / or lid based on parameters e.g. condition, quality, degree of contamination and presence of the respective base or lid at least in the primary circuit so that a required number and types of bases and lids are available in the second buildings for the production of assembled shelf-ready secondary packaging.

[0183] Unlike cardboard boxes, which often need to be disposed of and recycled after a single use, this method significantly reduces waste. Reusable shelf-ready secondary packaging with bases and lids that can be reused do not need to be manufactured again. Similarly, waste is reduced as each reused shelf-ready secondary packaging reduces the waste of such shelf-ready secondary packaging. By reusing the shelf-ready secondary packaging, the costs for procuring new materials and disposing of used cardboard boxes are reduced. The initially higher costs for manufacturing the shelf-ready secondary packaging are amortized through the longer usage duration and the lower ongoing costs for material and logistics. The cleaning units in the system ensure that the shelf-ready secondary packaging is thoroughly cleaned and disinfected after each use. This ensures high hygiene40261 / 4361 / PTWO 5 February 2025

[0184] 35

[0185] standards and the quality of goods presentation, which is particularly important in industries such as the food industry.

[0186] In an embodiment, the method comprises the further step of excluding used bases and / or lids from the primary circuit that cannot be reused due to damage or contamination, preferably the system is configured to perform this exclusion at the appropriate position in the primary circuit, for example in the first buildings, particularly preferably the system is configured so that each exclusion is documented by the system control.

[0187] In another embodiment, the method comprises the further steps of:

[0188] Transferring the bases and / or lids excluded from reuse to a secondary circuit with a recycling unit, preferably the excluded bases and / or lids are transported to the recycling unit by one or more vehicles;

[0189] Granulating the transferred bases and / or lids and manufacturing new bases and / or lids from the granulate as starting material in the recycling unit; and Feeding the new bases and / or lids produced in the recycling unit into the primary circuit, preferably in the first buildings as a logistical connection point between the primary and secondary circuits, particularly preferably the restored bases and / or lids are transported separately from each other in a flat form by one or more vehicles.

[0190] In summary, the described method offers a more sustainable, efficient, and cost-effective alternative to conventional cardboard box recycling by relying on durable, reusable materials and optimized logistics. The inventive method as a solution to the technical problem also achieves the same advantages as the inventive system. Therefore, all the advantages described above also apply here.

[0191] The term "a," "an," or "one" here does not denote a specific number of the components referred to but explicitly includes the possibility that the claimed subject matter may also comprise one or more of these components in addition to the one component. Thus, the term is also to be understood as "one or more." If the number of specified components is meant to be exactly 1 , this is indicated with "exactly one."40261 / 4361 / PTWO 5 February 2025

[0192] 36

[0193] The above described embodiments can be used individually or in any combination with each other, even in deviation from the back references of the dependent claims to each other stated in the claims.

[0194] Brief description of the drawings

[0195] These and other aspects of the invention are illustrated in detail in the following drawings.

[0196] Fig.1 : schematic view of the complexity and diversity of the system according to the present invention with interaction of the individual components (buildings);

[0197] Fig.2: view of an embodiment of the system according to the present invention comprising primary and secondary circuit as (a) a schematic pictogram and (b) a block diagram with system control;

[0198] Fig.3: an embodiment of the processes executed in the first building as a reconditioning center with continuous feeding of the sorting unit;

[0199] Fig.4: a schematic view of the incoming inspection of a base of the shelf-ready secondary packaging executed within the sorting unit;

[0200] Fig.5: a schematic view of a embodiment of the transport box with wall and base; Fig.6: a schematic view of base and lid of the shelf-ready secondary packaging and its corrugated material (a) being in erected form but still separate, and (b) as assembled shelf-ready secondary packaging; and

[0201] Fig.7: an embodiment of the method according to the present invention for operating a system according to Fig.2.

[0202] Detailed description of embodiments

[0203] Fig.1 shows a schematic view of the complexity and diversity of the system 1 according to the present invention with interaction of the individual components (buildings) 20, 70, 80. The system 1 has at least one primary circuit 1a for the reuse of the shelf-ready secondary packaging 10, 15 (explicitly shown in fig.6) for the suitable presentation and dispensing of primary packaging 50 (not shown here) with goods. The appearance of the primary packaging 50 can vary depending on the supplier of the goods filled within. The primary circuit 1a extends over a plurality of separate and spatially separated buildings 20, 70, 80, between which the shelf-40261 / 4361 / PTWO 5 February 2025

[0204] 37

[0205] ready secondary packaging 10, 15 are transported by means of vehicles 60. The system 1 comprises a plurality of these shelf-ready secondary packaging 10, 15 each consisting of more than 50% by weight of a corrugated plastic material, wherein the shelf-ready secondary packaging 10, 15 is designed in two parts and comprises a one-piece foldable base 10 consisting at least of a bottom 11 and side walls 12 surrounding the bottom 11 with a display side 12a, as well as a separate one-piece foldable lid 15, wherein the lid 15 and base 10 can be reversibly converted multiple times from a flat form 10k, 15k to an erected form 10h, 15h and back by folding along pre-formed fold lines, wherein the erected form 10h of the base 10 is intended for filling with primary packaging 50 containing goods, and the lid 15 is intended to be suitably assembled with the base 10 to enclose the primary packaging 60 as filled shelf-ready secondary packaging 10, 15 together with the filled base 10 at least during transport, wherein the base 10 and lid 15 each comprise at least one identification element 13 for uniquely identifying at least the types of base 10 and lid 15 and determining their positions in the system 1. For further details of the shelf-ready secondary packaging 10, 15 we refer to Fig. 6, 9, 10, 11 and 12.

[0206] Fig.2 shows a view of an embodiment of the system 1 according to the present invention for the reuse of shelf-ready secondary packaging 10, 15 (explicitly shown in fig.6) for the transport and suitable presentation and dispensing of goods-filled primary packaging 50 (not explicitly shown in the figures) comprising primary 1 a and secondary circuit 1b as (a) a schematic pictogram and (b) a block diagram with system control 7. The primary circuit (1a) extends over a plurality of separate and spatially separated buildings 20, 70, 80, between which the shelf-ready secondary packaging 10, 15 is transported by means of vehicles 60. There are one or more first buildings 20 for the automatic sorting S, cleaning and / or preparation RA and / or providing B of at least part of the returned used shelf-ready secondary packaging 10, 15 as reusable shelf-ready secondary packaging 10, 15 in separate processes for the bases 10 and lids 15. There are one or more second buildings 70 for the erection 10h, 15h, filling with primary packaging 50, and assembly of the bases 10 and lids 15 received separately in flat form 10k, 15k from the first buildings 20 into the filled shelf-ready secondary packaging 10, 15 with base 10 and lid 15. There are one or more third buildings 80 for receiving the filled shelf-ready secondary40261 / 4361 / PTWO 5 February 2025

[0207] 38

[0208] packaging 10, 15 from the base 10 and lid 15, removing the lids 15 from the bases 10, and offering the primary packaging 50 in the bases 10. There are vehicles 60 present for transporting the shelf-ready secondary packaging 10, 15 between at least the first, second, and third buildings 20, 70, 80, wherein:

[0209] (a) the bases 10 and lids 15 of the shelf-ready secondary packaging 10, 15 are transported separately in flat form between the first buildings 80 and the second buildings 70, 80,

[0210] (b) the bases 10 and lids 15 of the shelf-ready secondary packaging 10, 15 are transported in erected and assembled form carrying the primary packaging 50 between the second buildings 70 and the third buildings 80,

[0211] (c) the bases 10 and lids 15 of the shelf-ready secondary packaging 10, 15 are transported in any form 10k, 15k, 10e, 10h, 15h, preferably in flat form, from the third buildings 80 to the first buildings 20.

[0212] In order to obtain control over the system 1 a plurality of data exchange units 6 are distributed over the primary circuit 1a and are intended for reading the identification elements 13 of the shelf-ready secondary packaging 10, 15 and transmitting the reading data. A system control 7 controls the individual shelf-ready secondary packaging 10, 15 in the system 1 with their unique identification of base 10 and lid 15, their respective types, and their respective positions in the system 1 on their process paths based on the data transmitted by the data exchange units 6, and to control the reuse of base 10 and / or lid 15 based on parameters, e.g. condition, quality, degree of contamination and presence of the respective base 10 or lid 15 in at least the primary circuit 1a so that in the second buildings a required number and types of bases 10 and lids 15 are available for the production of assembled shelfready secondary packaging 10, 15. The system 1 is configured to exclude used bases 10 and / or lids 15 that cannot be reused due to damage or contamination from the primary circuit 1a, preferably the system 1 is configured to perform this exclusion at the appropriate position in the primary circuit 1 a, particularly preferably the system is configured such that each exclusion is documented by the system control 7. For one or more of the processes S, PA, B executed in the first building 20, a software SW is executed that uses machine learning and artificial intelligence through appropriate algorithms to support data analysis and process control in the sorting S, cleaning and / or preparation RA, and providing B of the shelf-ready secondary40261 / 4361 / PTWO 5 February 2025

[0213] 39

[0214] packaging 10, 15, including a classification of the bases 10 and lids 15 according to parameters, e.g. condition, quality, and degree of contamination based on the recorded conditions, qualities, and degrees of contamination on the bases 10 and lids 15, preferably, the machine learning is supervised learning using classifications and / or regression. The system 1 further comprises a secondary circuit 1b with a recycling unit 5 to granulate the excluded non-reusable bases 10 and / or lids 15 and to supply them for recovery from the granulate or other use, where the secondary circuit 1b is logistically linked to the primary circuit 1a in the one or more first buildings 20. The recycling unit 5 is designed to equip the manufactured bases 10 and lids 15 with the identification element 13 for the unique identification of the bases 10 and lids 15 and their types and to determine their positions in the system 1 by means of data exchange units 6, wherein the date of new manufacture, preferably also the date of first use of the original material, is stored in the identification element 13. The bases 10 and lids 15 manufactured with the recycling unit 5 are fed back into the primary circuit 1a in the one or more first buildings 20 as a logistical link between the primary and secondary circuits 1a, 1b. The recycling unit 5 may also provide new bases 10 and new lids 15 from raw material not resulting from granulation of rejected bases 10 and lids 15. Fig.2a shows the logistic connection with primary and secondary circuits 1a, 1b. Fig.2b shows the logistic and data connections between the parts, components and participants of primary and secondary circuits 1a, 1b.

[0215] Fig.3 shows an embodiment of the processes S, RA, B executed in the first building 20 as a re-conditioning center with continuous feeding of the sorting unit 21. The sorting S of the returned shelf-ready secondary packaging 10, 15 is carried out in the sorting unit 21 that includes at least first sensors 21 a, preferably an RFID reader, for reading the identification element 13, preferably an RFID transponder, of the base 10 and / or lid 15 of the shelf-ready secondary packaging 10, 15 to determine and classify the respective type of base 10 and lid 15, and at least second sensors 21 b for recording the condition and / or quality and / or degree of contamination of the base 10 or lid 15. The sorting unit 21 receives bases 10 and lids 15 in transport boxes 61 used as input container 23c and performs a sensor-based incoming inspection for the base 10 and lids 15 and to exclude the base 10 and / or lid 15 that40261 / 4361 / PTWO 5 February 2025

[0216] 40

[0217] has been classified as non-reusable due to e.g. condition, quality, and degree of contamination from the primary circuit 1a. The sorting unit 21 comprises a plurality of collection containers 23, 23a, 23b along a conveying means 24, here conveyor belt, and several gripping robots 22 as sorting means dedicated to certain collection container 23, 23a, 23b sorting the respective bases 10 and lids 15 into the suitable collection containers 23, 23a, 23b based on the classified condition, quality, and degree of contamination of the respective base 10 or lid 15, with each collection container 23 being assigned to different types and classifications of condition, quality, and degree of contamination. The container 23a may serve as a buffer container receiving content to be sorted later. The container 23b may serve as an intermediate storage e.g. to turn the bases or lids received in a wrong orientation. The sorting unit 21 hands over the sorted bases 10 and lids 15 to a cleaning unit 31 which is intended to clean and / or process RA the bases 10 and lids 15. The cleaning unit 31 comprises several cleaning lines, in this example two cleaning lines 31a, 31b, with respective processing stations 32 arranged in series. The individual cleaning lines 31a, 31b and their processing stations 32 are specifically intended for different cleaning methods RA based on the degree of contamination of the bases 10 and / or lids 15. For example, the cleaning line 31 a can be for dry cleaning RT and the cleaning line 31 b for wet cleaning RF or vice versa. Wet cleaning might be used in case of a higher degree of contamination. The sorting unit 21 provides the sorted bases 10 and lids 15 in collection containers 23 to handling robots 36, which take the bases 10 and lids 15 out of the collection containers 23 and put it on a conveyor belt 33 running through the cleaning unit 31. A first processing station 32a is set up to detect labels 14 on the bases 10 and remove them before cleaning the bases 10, preferably by blowing them off. The first processing station 32a is also shown in the cleaning lines 31b dedicated to lids 15 as an example in case of lids carrying any label. A second processing station 32b arranged behind the first processing station 32a carries out the cleaning process of the base 10 and the lid 15 by means of wet cleaning RF (in line 31a for bases 10), preferably by spraying with a cleaning fluid, and by means of dry cleaning RT (in line 31b for lids 10), preferably by mechanical brushing or air pressure cleaning. A third processing station 32c of the cleaning line 31a is arranged behind the second processing station 32b to dry the bases 10 cleaned with the preceding wet cleaning RF, preferably by means of a gas blower,40261 / 4361 / PTWO 5 February 2025

[0218] 41

[0219] heat radiation, or a spinning process. A fourth processing station 32d arranged behind the third processing station 32c in case of cleaning lines 31a and behind the second processing station 32b in case of cleaning lines 31b. The fourth processing station 32d is intended for disinfecting the bases 10 and lids 15, preferably by irradiation with suitable UV light. A fifth of the processing stations 32e is arranged behind the fourth processing station 32d intended for labeling at least the bases 10 after cleaning, wherein at least one base label 14a is applied to a prepared application surface 18 on at least one of the side walls 12 of the base 10. The fifth of the processing stations 32e may further apply a presentation label 14b in the form of the display side 12a for further designation of the product-filled primary packaging 50 to the display side 12a. The cleaning unit 31 is set up to carry out a sensor-based final inspection of the respective bases 10 and lids 15 after passing through the cleaning unit 31 and to classify them regarding condition, quality, and degree of contamination, and to exclude the bases 10 and lids 15 classified as non-reusable from the primary circuit 1a. The first building 20 further comprises a packing unit 41 for type-based sorting for bases 10 and lids 15, where bases 10 and lids 15 are packed separately for the future reuse of the bases 10 and lids 15, which have passed the cleaning unit 31. The bases 10 and lids 15 are delivered from the cleaning lines 31a, 31b by conveyer belts 42 of the packing units 41 and handled in the packing unit 41 by packing robots 43 to provide B the bases 10 and lids 15 in transport boxes 61. The packing robots 43 of the packing unit 41 place the bases 10 and lids 15 for separate transport in separate transport boxes 61 with respective side walls 61a, wherein the respective transport box 61 comprises one or more compartments 61b for receiving the bases 10 or the lids 15, which are placed as individual stacks by folding or flapping in a flat state 10k into the one or more compartments 61 b. The packing robots 43 of the packing unit 41 inserts one or more partition walls 61c on demand into the transport box 61 to divide the transport box 61 into several suitable compartments 61 b within the walls 61 a of the transport box 61. The packing unit 41 further stores data for the unique identification of the bases 10 and lids 15 transported with the transport box 61 in a machine-readable data storage 62 of the transport box 61. Further, the one or more first buildings 20 are set up to separate the bases 10 and lids 15 in the transport boxes 61 from other contents in the transport boxes 61 in a pre-sorting process, preferably the other40261 / 4361 / PTWO 5 February 2025

[0220] 42

[0221] contents are supplied for separate further use or disposal in the one or more first buildings 20.

[0222] Fig.4 shows as an example a schematic view of the incoming inspection of a base 10 of the shelf-ready secondary packaging 10, 15 executed within the sorting unit 21. The sorting unit 21 is configured to record parameters e.g. the condition, quality, and degree of contamination on both sides of the base 10 and lids 15 fully spread out in one plane, whereas the base 10 and / or lids 15 spread out in this way are preferably classified on a detection substrate 25, whereas it is particularly preferred, that a transparent detection substrate 25 is to be able to determine the condition, quality, and degree of contamination of both sides of the base 10 and lids 15 simultaneously. To determine the condition, quality, and degree of contamination of the base 10 and lids 15, optical sensors 21b are used to record images from the bases 10 and lids 15, which are analyzed by a software SW, preferably using machine learning. The content of the identification elements 13 of the base 10 and the lid 15 are read out by a suitable sensor 21a also connected to the analyzing software SW for further processing and forwarding the data to a data base and the system control 7.

[0223] Fig.5 shows a schematic view of an embodiment of the transport box 61 with walls 61a and a base 61 d. The transport box 61 is used for stacking a plurality of bases 10 or lids 15 of the shelf-ready secondary packaging 10, 15 in each flat form 10k, 15k for transporting either the base 10 or the lid 15 along the primary circuit 1a by means of vehicles 60 between first and second and / or third and first buildings 20, 70, 80. The transport box 61 comprises a compartment 61b per stack for receiving the base 10 or the lid 15 in flat form 10k, 15k, wherein the compartment 61b is adapted in width and / or length to the bases 10 and lids 15 so that they are tightly enclosed on at least two sides. The transport box 61 comprises one or more insertable partition walls 61c with which several suitable compartments 61b can be separated within the same transport box 61. The transport box 61 comprises a machine-readable data storage 62 in which data for the unique identification of the bases 10 and lids 15 transported with the transport box 61 can be stored. The transport box 61 will be closed with a cover lid 63 (shown without further details) after loading with bases 10 or lids 15.40261 / 4361 / PTWO 5 February 2025

[0224] 43

[0225] Fig.6 shows a schematic view of base 10 and lid 15 of the shelf-ready secondary packaging 10, 15 and its corrugated material CM (a) being in erected form 10h but still separate, and (b) as assembled shelf-ready secondary packaging 10, 15 consisting of more than 50% by weight of a corrugated plastic material (CM), preferably completely of corrugated plastic material CM, more preferred of the same corrugated plastic material CM, and is designed in two parts, wherein the shelfready secondary packaging 10, 15 comprises a one-piece foldable base 10 at least consisting of a bottom 11 and several side walls 12 surrounding the bottom with a display side 12a and a back side 12b as well as a separate one-piece foldable lid 15, wherein the lid 15 and base 10 can be reversibly converted multiple times from a flat state 10k, 15k to an erected form 10h, 15h and back by folding along prefabricated fold lines 10f, 15f, wherein the erected form 10h of the base 10 is intended for filling with primary packaging 50 containing goods, wherein the lid 15 is intended to be joined with the base 10 in an erected form 15h to enclose the primary packaging 60 as a filled shelf-ready secondary packaging 10, 15 together with the filled base 10 at least during transport, wherein the base 10 and lid 15 each comprise at least one identification element 13 for the unique identification of at least the types of base 10 and lid 15 and to determine their positions in the system 1. Here the identification element 13 is connected to the base 10 and the lid 15 at a suitable position. The identification element 13 is designed to be digitally written with data, preferably the identification element 13 is a data carrier that can be written to and read from using RF technology. The lid 15 comprises two support side walls 15b, 15c foldably connected to a lid surface 15a with a suitable height for placing on the bottom 11 of the base 10, wherein the support side walls 15b, 15c can be inserted between the primary packaging 50 and the corresponding opposite side walls 12 of the erected and filled base 10 along the side walls 12 of the base 10 when joined with the base 10. Different types of lids 15 might be provided for different heights of primary packaging 50, wherein the heights of the two opposite support side walls 15a, 15b of the respective lid type are adapted to the respective height of the primary packaging 50. In this embodiment the lid surface is surrounded by foldable side walls 15b, 15c, 15d. The base label 14a provides a surface for later apply specific information about the primary packaging (such as type of goods, manufacturing date, place of manufacture, etc.) onto the base label 14a. For this purpose, the base label40261 / 4361 / PTWO 5 February 2025

[0226] 44

[0227] 14a is a blank label not restricting the application technique to attach the specific information onto the base label 14a. Here, the base label 14a is attached to the back side 12b of the base 10 (side opposite to the display side 12a). In addition to the base label 14a, also a presentation label 14b in the form of the display side 12a can be applied onto the display side 12a of the base 10. A "presentation label" denotes a marking that is used as a flexible decoration principle to enable advertising and attention generation for the primary packaging 50 towards the customer. In order to be easily removable in the de-labeling station 32a, both labels 14a, 14b are applied onto an application surface 18 (only shown here on side 12b for the base label 14a). Alternatively, to the representation label 14b, a corresponding removable cover 17 might be connected of the display side 12a e.g. by fixing means of the display side 12a realized as one or more suitably dimensioned slots and the corresponding fastening means of the cover 17 realized as one or more suitably shaped tabs. The cover 17 serves the same purpose as the presentation label 14b.

[0228] The shelf-ready secondary packaging 10, 15 can be realized as a talking box, in which a NFC or HF RFID chip is particularly attached to the base 10. Information on the goods 50 can be read out by a customer from the chip, allowing for example barrier-free shopping, In particular, the information can be input by an entity of the second 70 or third building 80, where the manufacturer 70 or retailer 80 resides. The inventive talking box 10, 15 can also be applied in the inventive system 1.

[0229] Fig.7 shows an embodiment of the method 100 according to the present invention for operating a system 1 according to Fig.2 comprising the following steps of automatic processing 110 by sorting S, cleaning and / or reconditioning RA the bases 10 and lids 15 returned from the second or third buildings in the first buildings 20 in separate processes for bases 10 and lids 15 and providing B at least a part of the returned bases 10 and lids 15 as reusable shelf-ready secondary packaging 10, 15; transporting 120 the bases 10 and lids 15 of the shelf-ready secondary packaging 10, 15 in a flat form 10k, 15k separately to the second buildings 70 by one or more vehicles 60; erecting and filling 130 the bases 10 in the second buildings 70 with primary packaging 50 and joining the bases 10 and lids 15 to form shelf-ready secondary packaging 10, 15 filled with primary packaging 50; transporting 140 the erected 10h, 15h shelf-ready secondary packaging 10, 15 in a stacked state from40261 / 4361 / PTWO 5 February 2025

[0230] 45

[0231] the second buildings 70 to the third buildings 80 by one or more vehicles 60; receiving 150 the shelf-ready secondary packaging 10, 15 filled with primary packaging 50 in the third buildings 80 and removing the lids 15 from the respective bases 10 to offer the primary packaging 50 in the bases 10; returning 160 used bases 10 and lids 15 in a flat form 10k, 15k or another state from one or more second or third buildings 80 to one or more first buildings 20 by one or more vehicles 60; controlling 170 the system 1 by means of a system control 7 using a plurality of data exchange units 6 distributed over the primary circuit 1a for reading the identification elements 13 of the shelf-ready secondary packaging 10, 15 and for transmitting data from the reading, which are suitably connected to the system control, wherein the system control 7 is intended to control the individual shelf-ready secondary packaging 10, 15 in the system 1 with their unique identification of base 10 and lid 15, their respective types, and their respective positions in the system 1 on their process paths and, based on the knowledge of the data for each base 10 and lid 15 of the shelf-ready secondary packaging 10, 15 at least along the primary circuit 1a, to control the reuse of base 10 and / or lid 15 based on parameters e.g. condition, quality, degree of contamination and presence of the respective base 10 or lid 15 at least in the primary circuit 1a so that a required number and types of bases 10 and lids 15 are available in the second buildings for the production of assembled shelfready secondary packaging 10, 15. The method further comprises the step of excluding 180 used bases 10 and / or lids 15 from the primary circuit 1a that cannot be reused due to damage or contamination, preferably the system 1 is configured to perform this exclusion 180 at the appropriate position in the primary circuit 1a, for example in the first buildings 20, particularly preferably the system is configured so that each exclusion 180 is documented by the system control 7. The method 100 further comprises the steps of transferring 190 the bases 10 and / or lids 15 excluded from reuse to a secondary circuit 1 b with a recycling unit 5, preferably the excluded bases 10 and / or lids 15 are transported to the recycling unit 5 by one or more vehicles 60; granulating the transferred bases 10 and / or lids 15 and manufacturing new bases 10 and / or lids 15 from the granulate as starting material in the recycling unit 5 as step 200; and feeding 210 the bases 10 and / or lids 15 produced in the recycling unit 5 into the primary circuit 1a, preferably in the first buildings 20 as a logistical connection point between the primary and secondary circuits 1a, 1b,40261 / 4361 / PTWO 5 February 2025

[0232] 46

[0233] particularly preferably the manufactured new bases 10 and / or lids 15 are transported separately from each other in a flat form 10k, 15k by one or more vehicles 60.

[0234] The embodiments shown here are only examples of the present invention and must therefore not be understood as restrictive. Alternative embodiments considered by skilled people are equally covered by the scope of protection of the present invention.40261 / 4361 / PTWO 5 February 2025

[0235] 47

[0236] List of Reference numbers

[0237] 1 inventive system

[0238] 1 a primary circuit of the inventive system

[0239] I b secondary circuit of the inventive system

[0240] 10 base of shelf-ready secondary packaging

[0241] 10, 15 shelf-ready secondary packaging (e.g. talking box)

[0242] 10e completely spread out form of base or lid

[0243] 10f foldable line of the base

[0244] 10h erected form of the base for carrying primary packaging containing goods

[0245] 10k flat form of the base

[0246] I I bottom of the base

[0247] 12 side walls of the base

[0248] 12a display side of the base

[0249] 12b side wall opposite of the display side

[0250] 13 identification element of the base and / or the lid

[0251] 14a base label

[0252] 14b presentation label for further designation of the product-filled primary packaging

[0253] 15 lid of shelf-ready secondary packaging

[0254] 15a lid surface

[0255] 15b, c support side wall of the lid

[0256] 15d foldable side wall of the lid surface

[0257] 15f foldable line of the lid

[0258] 15h erected form of the lid for carrying primary packaging containing goods 15k flat form of the lid

[0259] 17 cover

[0260] 18 application surface of base or lid

[0261] 20 first building(s) (reconditioning center)

[0262] 21 sorting unit

[0263] 21 a first sensors of the sorting unit

[0264] 21 b second sensors of the sorting unit

[0265] 22 sorting means, preferably gripping robots40261 / 4361 / PTWO 5 February 2025

[0266] 48

[0267] 23 collection containers

[0268] 23a additional second (buffer) collection containers

[0269] 23b additional third (intermediate storage) collection containers

[0270] 23c input container

[0271] 24 conveying means

[0272] 25 detection substrate

[0273] 31 cleaning unit

[0274] 31a, 31b cleaning line

[0275] 32a first processing station (de-labeling)

[0276] 32b second processing station (cleaning)

[0277] 32c third processing station (drying)

[0278] 32d fourth processing station (disinfecting)

[0279] 32e fifth processing station (labeling)

[0280] 33 conveyer belt of the cleaning unit

[0281] 36 handling robot

[0282] 41 packing unit

[0283] 42 conveyer belt of the packing unit

[0284] 43 packing robot

[0285] 5 recycling unit

[0286] 6 data exchange unit

[0287] 7 system control

[0288] 50 goods-filled primary packaging

[0289] 60 vehicles for the transport of the base and lids, as well as the assembled shelf-ready secondary packaging in a suitable transport box between the different buildings

[0290] 61 transport for the bases and / or lids

[0291] 61 a side wall of the transport box

[0292] 61 b compartments for receiving the bases and lids

[0293] 61 c partition walls inside of the transport box

[0294] 61 d bottom of the transport box

[0295] 61 e groove or ledge for attaching the transport walls of the transport box 62 machine-readable data storage of the transport box

[0296] 63 cover lid of the transport box40261 / 4361 / PTWO 5 February 2025

[0297] 49

[0298] 70 second building(s), e.g. manufacturer buildings for filling the bases with goods-filled primary packaging

[0299] 80 third building(s), e.g. supermarkets for selling goods

[0300] 100 a method for operating a system for reuse of shelf-ready secondary packaging according to the present invention

[0301] 110 automatic processing the bases and lids in the first buildings

[0302] 120 transporting the bases and lids in a flat form to the second buildings 130 erecting and filling the bases with primary packaging and form with the lids the shelf-ready secondary packaging in the second buildings 140 transporting the shelf-ready secondary packaging to the third buildings 150 Receiving the shelf-ready secondary packaging with primary packaging and offering the primary packaging in the third buildings

[0303] 160 Returning used bases and lids to the first buildings

[0304] 170 Controlling the system by means of a system control

[0305] 180 excluding non-reusable bases and lids from the primary circuit

[0306] 190 Transferring the non-reusable bases and lids to a secondary circuit 200 granulating excluded bases and lids and manufacturing new bases and / or lids from the granulate as starting material in the recycling unit 210 Feeding the new bases and / or lids produced in the recycling unit into the primary circuit

[0307] B providing (sorting and packaging)

[0308] CM corrugated material

[0309] S sorting

[0310] SW software

[0311] RA cleaning and / or preparation

[0312] RF wet cleaning

[0313] RT dry cleaning

Claims

40261 / 4361 / PTWO 5 February 202550Claims1. A system (1 ) with at least one primary circuit (1 a) for the reuse of shelf-ready secondary packaging (10, 15) for the transport and suitable presentation and dispensing of goods-filled primary packaging (50), wherein the primary circuit (1a) extends over a plurality of separate and spatially separated buildings (20, 70, 80), between which the shelf-ready secondary packaging (10, 15) is transported by means of vehicles (60), comprising:a plurality of these shelf-ready secondary packaging (10, 15), each consisting of more than 50% by weight of a corrugated plastic material (CM), wherein the shelf-ready secondary packaging (10, 15) is designed in two parts and comprises a one-piece foldable base (10) consisting at least of a bottom (11) and side walls (12) surrounding the bottom (11) with a display side (12a), as well as a separate one-piece foldable lid (15), wherein the lid (15) and base (10) can be reversibly converted multiple times from a flat form (10k, 15k) to an erected form (1 Oh, 15h) and back by folding along pre-formed fold lines (1 Of, 15f), wherein the erected form (10h) of the base (10) is intended for filling with primary packaging (50) containing goods, and the lid (15) is intended to be suitably assembled with the base (10) to enclose the primary packaging (60) as filled shelfready secondary packaging (10, 15) together with the filled base (10) at least during transport, wherein the base (10) and lid (15) each comprise at least one identification element (13) for uniquely identifying at least the types of base (10) and lid (15) and determining their positions in the system (1);one or more first buildings (20) for the automatic sorting (S), cleaning and / or preparation (RA) and / or providing (B) of at least part of the returned used shelf-ready secondary packaging (10, 15) as reusable shelf-ready secondary packaging (10, 15) in separate processes for the bases (10) and lids (15);one or more second buildings (70) for the erection (1 Oh, 15h), filling with primary packaging (50), and assembly of the bases (10) and lids (15) received separately in flat form (10k, 15k) from the first buildings (20) into40261 / 4361 / PTWO 5 February 2025 51the filled shelf-ready secondary packaging (10, 15) with base (10) and lid (15);one or more third buildings (80) for receiving the filled shelf-ready secondary packaging (10, 15) from the base (10) and lid (15), removing the lids (15) from the bases (10), and offering the primary packaging (50) in the bases (10);Vehicles (60) for transporting the shelf-ready secondary packaging (10, 15) between at least the first, second, and third buildings (20, 70, 80), whereino the bases (10) and lids (15) of the shelf-ready secondary packaging (10, 15) are transported separately in flat form between the first buildings (80) and the second buildings (70, 80),o the bases (10) and lids (15) of the shelf-ready secondary packaging (10, 15) are transported in erected and assembled form carrying the primary packaging between the second buildings (70) and the third buildings (80),o the bases (10) and lids (15) of the shelf-ready secondary packaging (10, 15) are transported in any form (10k, 15k, 10e, 10h, 15h), preferably in flat form, from the third buildings (80) to the first buildings (20);a plurality of data exchange units (6) distributed over the primary circuit (1 a) and intended for reading the identification elements (13) of the shelfready secondary packaging (10, 15) and transmitting the reading data; a system control (7) intended to control the individual shelf-ready secondary packaging (10, 15) in the system (1) with their unique identification of base (10) and lid (15), their respective types, and their respective positions in the system (1) on their process paths based on the data transmitted by the data exchange units (6), and to control the reuse of base (10) and / or lid (15) based on parameters, e.g. condition, quality, degree of contamination and presence of the respective base (10) or lid (15) in at least the primary circuit (1 a) so that in the second buildings a required number and types of bases (10) and lids (15) are available for the production of assembled shelf-ready secondary packaging (10, 15).40261 / 4361 / PTWO 5 February 2025522. The system (1 ) according to claim 1 , whereinthe system (1) is configured to exclude used bases (10) and / or lids (15) that cannot be reused due to damage or contamination from the primary circuit (1a), preferably the system (1) is configured such that each exclusion is documented by the system control (7).

3. The system (1 ) according to claim 1 or 2, whereinfor one or more of the processes (S, PA, B) in the first building (20), a software (SW) is executed that uses machine learning and artificial intelligence through appropriate algorithms to support data analysis and process control in the sorting (S), cleaning and / or preparation (RA), and providing (B) of the shelfready secondary packaging (10, 15), including a classification of the bases (10) and lids (15) according to parameters, e.g. condition, quality, and degree of contamination based on the recorded conditions, qualities, and degrees of contamination on the bases (10) and lids (15), preferably, the machine learning is supervised learning using classifications and / or regression.

4. The system (1 ) according to one of the preceding claims, whereinthe sorting (S) of the returned shelf-ready secondary packaging (10, 15) is carried out in a sorting unit (21 ) configured to perform a sensor-based incoming inspection for the base (10) and lids (15) and to exclude the base (10) and / or lid (15) that has been classified as non-reusable due to e.g. condition, quality, and degree of contamination from the primary circuit (1a).

5. The system (1 ) according to claim 4, whereinthe sorting unit (21 ) which comprises at least first sensors (21a), preferably an RFID reader, for reading the identification element (13), preferably an RFID transponder, of the base (10) and / or lid (15) of the shelf-ready secondary packaging (10, 15) to determine and classify the respective type of base (10) and lid (15), and at least second sensors (21b) for recording the condition and / or quality and / or degree of contamination of the base (10) or lid (15).

6. The system (1 ) according to claim 4 or 5, whereinthe sorting unit (21) comprises a plurality of collection containers (23) and one or more sorting means (22), preferably gripping robots (22), which are40261 / 4361 / PTWO 5 February 202553designed to enable a type-based sorting of the respective bases (10) and lids (15) into the collection containers (23) based on parameters e.g. the classified condition, quality, and degree of contamination of the respective base (10) or lid (15), with each collection container (23) being assigned to different types and classifications of e.g. condition, quality, and degree of contamination.

7. The reconditioning center (20) according to any of claims 4 to 6, wherein the sorting unit (21 ) comprises a pre-sorting station designed to separate the used bases (10) and lids (15) in the received transport boxes (61) from other contents in the transport boxes (61) by means of appropriate classification of the content by the sorting unit (21) using suitable sensors (21a, 21b) for recognizing the content, preferably the other content in the sorting unit (21 ) are fed to a separate further use or disposal outside the primary circuit (1a).

8. The system (1 ) according to any one of the preceding claims, wherein the first building (20) comprises a cleaning unit (31) which is intended to clean and / or process (RA) the bases (10) and lids (15) handed over by the sorting unit (21), for which purpose the cleaning unit (31) comprises one or more cleaning lines (31a, 31b) with respective multiple processing stations (32a-e) arranged in series.

9. The system (1 ) according to claim 8, whereinthe multiple processing stations (32a-e) are one or more processing stations ofa first of the processing stations (32a) to detect and remove labels (14a, 14b) before cleaning;a second of the processing stations (32b) carrying out the cleaning process of the base (10) and / or the lid (15) by means of wet cleaning (RF) and / or by means of dry cleaning (RT);a third of the processing stations (32c) drying the bases (10) and / or lids (15) cleaned with the preceding wet cleaning (RF);a fourth of the processing stations (32d) for disinfecting the bases (10) and / or lids (15) arranged behind the second or third processing station (32c);40261 / 4361 / PTWO 5 February 202554a fifth of the processing stations (32e) for labeling at least the bases (10) after cleaning or disinfecting, wherein at least one base label (14a) is applied to one side wall (12b) of the base (15), and / or a presentation label (14b) or removable cover (17) in the form of the display side (12a) is applied or connected to the display side (12a), both on top of a prepared application surface (18).

10. The system (1 ) according to claim 8 or 9, whereinthe cleaning unit (31) is set up to carry out a sensor-based final inspection of the respective bases (10) and lids (15) after passing through the cleaning unit (31) and to classify them regarding condition, quality, and degree of contamination, and to exclude the bases (10) and lids (15) classified as non- reusable from the primary circuit (1a).

11. The system (1 ) according to one of the preceding claims, whereinthe first building (20) comprises a packing unit (41 ) for type-based sorting and packaging (B) of bases (10) and lids (15), which have passed the cleaning lines (31a, 31b), in separate transport boxes (61) each comprise a bottom (61 d) of the box (61) and side walls (61a) of the box (61) around the bottom (61 d) of the box (61), where the bases (10) and lids (15) are packed as individual stacks by folding or flapping the bases (10) or the lids (15) in a flat state (10k, 15k) into one or more compartments (61 b) of the transport box (61 ), to provide (B) reusable shelf-ready secondary packaging (10, 15) for further use.

12. The system (1 ) according to claim 11 , whereinthe packing unit (41) is intended to perform one or more of the following processes:to insert one or more partition walls (61c) into the transport box (61) to divide the transport box (61) into several suitable compartments (61b) within the walls (61 a) of the transport box (61 );to close the transport box (61 ) with a cover lid (63);40261 / 4361 / PTWO 5 February 202555to store data for the unique identification of the bases (10) and lids (15) transported with the transport box (61) in a machine-readable data storage (62) of the transport box (61 ).

13. The system (1 ) according to any of the preceding claims, whereinthe system (1) further comprises a secondary circuit (1b) logistically linked to the primary circuit (1a) in the one or more first buildings (20) to transfer excluded bases (10) and lids (15) from the primary circuit (1 a) to the secondary circuit (12b) and newly manufactured bases (10) and lids (15) back to the primary circuit (1a), and a recycling unit (5) to granulate the excluded non- reusable bases (10) and / or lids (15) and to manufacture the new bases (10) and lids (15) from the granulate or to supply them for other use.

14. The system (1) according to claim 13, whereinthe recycling unit (5) is designed to equip the new bases (10) and lids (15) with the identification elements (13), wherein the date of new manufacture, preferably also the date of first use of the original material, is stored in the identification element (13) by means of data exchange units (6) distributed over the secondary circuit (1 b).

15. The system (1 ) according to any of the preceding claims, whereinthe shelf-ready secondary packaging (10, 15) is a talking box, in which a NFC or HF RFID chip is particularly attached to the base (10), from which information on the goods (50) can be read out by a customer, in particular, the information can be input by an entity of the second (70) or third building (80).

16. A shelf-ready secondary packaging (10, 15) for use in a system (1) according to any of claims 1 to 15, wherein the shelf-ready secondary packaging (10, 15) is designed in two parts comprising a one-piece foldable base (10) at least consisting of a bottom (11) and several side walls (12) surrounding the bottom with a display side (12a) as well as a separate one-piece foldable lid (15), wherein the lid (15) and base (10) can be reversibly converted multiple times from a flat state (10k, 15k) to an erected form (1 Oh, 15h) and back by folding along pre-fabricated fold lines (1 Of, 15f), wherein the erected form (10h) of the base (10) is intended for filling with primary packaging (50) containing goods,40261 / 4361 / PTWO 5 February 202556wherein both base (10) and lid (15) consist of more than 50% by weight of a corrugated plastic material (CM), wherein the lid (15) is intended to be joined with the base (10) in a suitable form to enclose the primary packaging (60) as a filled shelf-ready secondary packaging (10, 15) together with the filled base (10) at least during transport, wherein the base (10) and lid (15) each comprise at least one identification element (13) for the unique identification of at least the types of base (10) and lid (15) and to determine their positions in the system (1), preferably the identification element (13) is connected to or integrated into the base (10) or lid (15) at a suitable position.

17. The shelf-ready secondary packaging (10, 15) according to claim 16, wherein the identification element (13) is designed to be digitally written with data, preferably the identification element (13) is a RF Tag, which can be written to and read from using RF technology.

18. The shelf-ready secondary packaging (10, 15) according to claim 16 or 17, whereinthe lid (15) comprises at least two support side walls (15b, 15c) foldably connected to a lid surface (15a) to be inserted between the primary packaging (50) and the corresponding opposite side walls (12) of the erected and filled base (10) along the side walls (12) of the base (10) when joined with the base (10), where the support side walls (15b, 15c) have a suitable height rest on the bottom (11) of the base (10), preferably the lid surface (15a) is completely surrounded by foldable side walls (15b, 15c, 15d).

19. The shelf-ready secondary packaging (10, 15) according to claim 18, wherein different types of lids (15) are provided for different heights of primary packaging (50), wherein the heights of the two opposite support side walls (15b, 15c) of the respective lid type are adapted to the respective height of the primary packaging (50).

20. The shelf-ready secondary packaging (10, 15) according to any of claims 16 to 19, whereinat least the base (10) comprises an application surface (18) on at least one of the side surfaces (12), preferably the side surface (12b) opposite the display40261 / 4361 / PTWO 5 February 202557surface (12a), for applying a base label (14a) thereon, which specifically reduces the adhesion of the base label (14a) on the application surface (18) to achieve sufficient adhesion of the base label (14a) during a cycle in the primary circuit (1) and to enable easy removal of the base label (14a) in the cleaning unit (31 , 32a) by blowing off, preferably the application surface (18) completely covers the side surface (12b) opposite the display surface (12a).

21. The shelf-ready secondary packaging (10, 15) according to claim 20, wherein the application surface (18) is provided by a silicone coating of the side surface (12, 12b) or by a permanently remaining silicone-coated base label (18) on the side surface (12, 12b).

22. The shelf-ready secondary packaging (10, 15) according to claim 20 or 21, whereinthe application surface (18) is additionally present on the display surface (12a) for the reversible application of a presentation label (14b), preferably this application surface (18) completely covers the display side (12a).

23. The shelf-ready secondary packaging (10, 15) according to any of claims 16 to 22, whereinthe base (10) comprises a reversibly attachable and removable cover (17) that can be placed on the display side (12a) from the outside, wherein the display side (12a) comprises fastening means, preferably one or more suitably dimensioned slots, which interact with corresponding fastening means of the cover (17), preferably one or more suitably shaped tabs, to fix them together.

24. The shelf-ready secondary packaging (10, 15) according to any of the claims 16 to 23, whereinthe shelf-ready secondary packaging (10, 15) is a talking box, in which a NFC or HF RFID chip is particularly attached to the base (10), from which information on the goods (50) can be read out by a customer, in particular, the information can be input by an entity of the second (70) or third building (80).

25. A transport box (61) with at least one stack of a plurality of bases (10) or lids (15) of the shelf-ready secondary packaging (10, 15) each in flat form (10k,40261 / 4361 / PTWO 5 February 20255815k) according to any of claims 16 to 24 for transporting either the stacked bases (10) or lids (15) at least along a primary circuit (1 a) by means of vehicles (60) between first and second and / or third and first buildings (20, 70, 80) in the primary circuit (1a), wherein the transport box (61) comprises a bottom of the box (61 d) and a side wall of the box (61a) surrounding the bottom of the box (61 d) defining at least one compartment (61b) for receiving the stacked bases (10) or lids (15), wherein the compartment (61b) is adapted in width and / or length to the bases (10) and lids (15) in flat form (10k, 15k) so that they are tightly enclosed on at least two sides, preferably the surrounding side wall of the box (61a) is a one piece side wall (61a) from interconnected walls, which are foldable to be able to store the side wall (61 a) of the box in a flat form.

26. The transport box (61 ) according to claim 25, whereinthe transport box (61) comprises one or more insertable partition walls (61c) with which the transport box (61) is divided into several separate compartments (61b).

27. The transport box (61 ) according to claim 25 or 26, whereinthe transport box (61) comprises a machine-readable data storage (62) in which data for the unique identification of the bases (10) and lids (15) transported with the transport box (61 ) can be stored.

28. The transport box (61 ) according to one of claims 25 to 27, whereinthe bottom (61 d) of the box has a surrounding groove or ledge (61 e) so that the side wall (61a) of the box can be inserted into the groove (61 e) or onto the ledge (61 e) in one piece.

29. The transport box (61 ) according to one of claims 25 to 28, whereinthe transport box has a cover lid (63) to be placed onto the side wall (61a) of the box to close a transport volume of the transport box (61 ).

30. A method (100) for operating a system (1 ) according to any one of claims 1 to 15 with at least one primary circuit (1a) for the reuse of two-part shelf-ready secondary packaging (10, 15) made of separate joinable bases (10) and lids (15) according to any one of claims 16 to 24, which include at least one40261 / 4361 / PTWO 5 February 202559identification element (13) for uniquely identifying at least the types of base (10) and lid (15) and for determining their positions in the system (1) for the appropriate presentation and delivery of goods (50), wherein the primary circuit (1a) extends over a plurality of separate and spatially separated buildings (20, 70, 80), the method (100) comprising the following steps:Automatic processing (110) by sorting (S), cleaning and / or reconditioning (RA) the bases (10) and lids (15) returned from the second or third buildings in the first buildings (20) in separate processes for bases (10) and lids (15) and providing (B) at least a part of the returned bases (10) and lids (15) as reusable shelf-ready secondary packaging (10, 15);Transporting (120) the bases (10) and lids (15) of the shelf-ready secondary packaging (10, 15) in a flat form separately to the second buildings (70) by one or more vehicles (60);Erecting and filling (130) the bases (10) in the second buildings (70) with primary packaging (50) and joining the bases (10) and lids (15) to form shelf-ready secondary packaging (10, 15) filled with primary packaging (50);Transporting (140) the erected shelf-ready secondary packaging (10, 15) in a stacked state carrying the primary packaging (50) from the second buildings (70) to the third buildings (80) by one or more vehicles (60);Receiving (150) the shelf-ready secondary packaging (10, 15) filled with primary packaging (50) in the third buildings (80) and removing the lids (15) from the respective bases (10) to offer the primary packaging (50) in the bases (10);Returning (160) used bases (10) and lids (15) in a flat form (10k, 15k) or another state (10k, 15k, 10e, 10h, 15h) from one or more second or third buildings (80) to one or more first buildings (20) by one or more vehicles (60);Controlling (170) the system (1 ) by means of a system control (7) using a plurality of data exchange units (6) distributed over the primary circuit (1a) for reading the identification elements (13) of the shelf-ready40261 / 4361 / PTWO 5 February 202560secondary packaging (10, 15) and for transmitting data from the reading, which are suitably connected to the system control, wherein the system control (7) is intended to control the individual shelf-ready secondary packaging (10, 15) in the system (1) with their unique identification of base (10) and lid (15), their respective types, and their respective positions in the system (1) on their process paths and, based on the knowledge of the data for each base (10) and lid (15) of the shelf-ready secondary packaging (10, 15) at least along the primary circuit (1a), to control the reuse of base (10) and / or lid (15) based on parameters e.g. condition, quality, degree of contamination and presence of the respective base (10) or lid (15) at least in the primary circuit (1a) so that a required number and types of bases (10) and lids (15) are available in the second buildings for the production of assembled shelf-ready secondary packaging (10, 15).

31. The method according to claim 30, comprising the further step of excluding (180) used bases (10) and / or lids (15) from the primary circuit (1a) that cannot be reused due to damage or contamination, preferably the system (1) is configured to perform this exclusion (180) in the first buildings (20), particularly preferably the system is configured so that each exclusion (180) is documented by the system control (7).

32. The method (100) according to claim 31, wherein the method, following step (180), comprises the further steps of:Transferring (190) the bases (10) and / or lids (15) excluded from reuse to a secondary circuit (1b) with a recycling unit (5), preferably the excluded bases (10) and / or lids (15) are transported to the recycling unit (5) by one or more vehicles (60);Granulating the transferred bases (10) and / or lids (15) and manufacturing (200) new bases (10) and / or lids (15) from the granulate as starting material in the recycling unit (5); and Feeding (210) the new bases (10) and / or lids (15) produced in the recycling unit (5) into the primary circuit (1a), preferably in the first buildings (20) as a logistical connection point between the primary and40261 / 4361 / PTWO 5 February 2025 61secondary circuits (1a, 1b), particularly preferably the restored bases (10) and / or lids (15) are transported separately from each other in a flat form (10k, 15k) by one or more vehicles (60).

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