Reusable Nestable Modular Containers for CPG Reverse Logistics

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Solution Overview

Problem

Current consumer packaged goods (CPG) packaging is designed for one-way shipping and single use, leading to high logistics costs and inefficiencies in reverse logistics due to non-nestable and varied container formats.

Innovation Solution

A reusable container ecosystem with nestable modular components that allow for shared or 'pooled' packaging across brands, enabling efficient storage and transportation by allowing containers to be stacked and nested.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If current CPG packaging is designed for one-way shipping and single use, then manufacturing and distribution are simplified, but reverse logistics costs increase and sustainability deteriorates

Engineering Contradiction:

Improvepackaging manufacturing simplicityVSAvoidreverse logistics cost

Core Design Contradiction:

Ease of manufactureVSLoss of energy

Solution Approach 1:

The packaging system is divided into separate modular components (container body, lid, label, closure) that can be manufactured independently and assembled at the point of use. This segmentation enables standardized production of simple components while facilitating efficient return and reuse of the same components across multiple cycles, reducing reverse logistics costs.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The container components are designed with nested structures where smaller components fit within larger ones (e.g., lids nesting in container openings, labels nesting on container surfaces). This nesting enables compact storage and transportation of returnable packaging, significantly reducing the space and cost required for reverse logistics operations.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Adaptability or versatility

If containers come in different sizes, shapes, and configurations unique to manufacturers, then product-specific packaging needs are met, but collection and sorting complexity increases

Engineering Contradiction:

Improvepackaging format varietyVSAvoidcollection and sorting complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

A universal container platform is designed with standardized interfaces and attachment mechanisms that allow the same basic container structure to accommodate various products and configurations through modular components. This universality enables single-stream collection and simplifies sorting operations while maintaining the ability to serve multiple product categories and manufacturer needs.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The packaging system incorporates dynamic or adjustable components that can be configured for different product types while maintaining the same overall structure. For example, adjustable lids, removable labels, and reconfigurable closures allow a single container design to adapt to various product requirements without increasing collection and sorting complexity.

Inventive Principle:

Principle #15Dynamics

3Reliability

If containers are not nestable, then structural integrity and ease of use are maintained, but storage and transportation space requirements increase

Engineering Contradiction:

Improvecontainer structural integrityVSAvoidstorage and transportation space

Core Design Contradiction:

ReliabilityVSVolume of stationary object

Solution Approach 1:

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The nesting design utilizes three-dimensional space efficiently by arranging components in nested dimensions rather than side-by-side. This dimensional arrangement maximizes space utilization during storage and transportation while maintaining the structural integrity and functional reliability of each individual component.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

4Loss of energy

If reusable containers are implemented, then sustainability and cost per use improve, but collection velocity decreases due to varied packaging formats

Engineering Contradiction:

Improvecost per useVSAvoidcollection velocity

Core Design Contradiction:

Loss of energyVSProductivity

Solution Approach 1:

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

Multiple packaging formats and container types are merged into a single standardized platform that can be collected together in one stream. This consolidation eliminates the need for separate collection and sorting operations for different packaging types, dramatically increasing collection velocity while maintaining cost-effectiveness through shared infrastructure.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS20250100759A1Reusable containers for consumer packaged goods with nestable modular components

Publication Date: 2025.03.27 ORORA PACKAGING SOLUTIONS

AI summary

A system of reusable and nestable containers for consumer-packaged goods comprising modular components including different size and configuration cup portions configured to nest with one another to be stackable for storage and shipping; bottle top portions removably coupled to the cup portions and nest with one another to be stackable for storage and shipping; and lid portions removably coupled to the cup portions and being configured to nest with one another to be stackable for storage and shipping. The containers allow for shared or “pooled” packaging across brands designed to nest for reverse logistics.