This story originally appeared in the December 2025 issue of Modern Materials Handling.
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As warehouse and DC operations evolve, tote and container design and functionality are changing right along with them. The market is shifting toward products that integrate more easily with automation, support sustainability goals, and simplify work on the floor. Here are six key trends shaping the next generation of totes and containers.
1. Automation-ready by design
As automation spreads through warehouses, totes and containers have to perform as part of the system. Breanna Herbert, senior product manager of automotive and industrial at ORBIS Corp., says companies are investing heavily in automation and robotics and now expect packaging to keep up.
“They’re seeking automation-friendly design features like slots for vertical lifting, dimensional consistency, and flat surfaces for labels to be read by vision systems and other readers,” Herbert says.
Reusable totes are molded for precise dimensional consistency, which helps them move smoothly through conveyors, shuttles, and robotic handling systems. Herbert says this repeatable performance allows them to “interface seamlessly with equipment within the plant” and ship efficiently on standard pallets and trailers.
Even minor packaging flaws can stop a system. Torn flaps or warped bins cause jams, while consistent totes keep work flowing.
“When a warehouse is using automation, a consistent tote or pallet can prevent the inconsistencies seen in expendable packaging that cause system downtime,” says Herbert, who adds that automation-ready designs have become the new baseline for companies focused on speed and accuracy.
2. Customization shapes modern container design
The pace and depth of automation adoption are changing quickly. Green at MDI says warehouses and distribution centers are now “gearing up and installing a lot of this automation for their facilities even more now than we’ve seen in the past.”
As companies bring in more bots, mobile robots, and automated storage systems, they’re finding that one-size-fits-all packaging no longer works.
“We’re developing customized solutions for a lot of the automation, especially the little ibots that many of these warehouse distribution centers are purchasing,” says Green. “Not every warehouse is moving the same products, so they need something that fits what they’re doing.”
In response to this shift, MDI is engineering containers designed specifically for automated systems and the products they handle. The company is also working closely with customers to create totes that move through different forms of automation without jamming, tipping or wearing out too soon. Green expects the focus on customization to continue to grow as companies add new systems. He says the goal is simple: make automation fit the space, not the other way around.
3. One container manages every step in the process
At a major athletic footwear manufacturer’s distribution center, Flexcon’s molded plastic totes move through the entire operation without being swapped or repacked.
Cole Beckerman, manager of marketing and development at Flexcon, recently visited the site to film and photograph the system in action, and he says the setup captures what many automated warehouses are trying to achieve: seamless movement from order to shipment.
The operation uses a single container type from start to finish. Once an order is placed, a shuttle retrieves the tote from an automated storage and retrieval system (AS/RS) and sends it across conveyors to a goods-to-person workstation. There, workers pick from a range of SKUs, drop items into the same tote, and send it forward with a quick toggle switch.
The container travels up to 40 miles per hour through vertical shuttles before reaching the packing area, where the order is boxed and shipped.
Beckerman says using one tote across so many touchpoints simplifies integration and reduces downtime. Every system, from shuttles to robots, can handle the same container, and installers already know the tolerances. “Anytime they add new stations or upgrade automation, everything still fits,” he says. “It’s faster, cleaner, and there’s no mismatch between systems.”
4. Designing for ergonomics and durability
Warehouse and DC operators want equipment that lasts longer, performs better, and supports daily workflows.
Green says MDI’s customers are looking for durability and increased longevity in their containers. “The whole idea is reusing and keeping it within the system and operating as long as possible,” he says. “That increases efficiency and lessens downtime from changing out containers.”
That same design focus now extends to how workers interact with each container. Green says MDI asks clients a series of questions before production even begins. “We’re asking them upfront about the basket of products that will go into the container, how much it will weigh, and how often it will be handled,” he says. Those answers guide ergonomic choices like handle placement, hand-hole offset, and whether lids should open automatically to reduce repetitive motion.
The company is also refining materials and engineering choices to improve performance and extend lifespan. Green says the goal is to extend container life while improving their performance in both automated and manual workflows.
5. Rethinking lower-level storage space
Warehouses are also getting creative with the space closest to the floor. Beckerman says many operations now fill the lower levels of racking with bins or containers instead of building new shelving. “If the first rack is at head height, they’ll fill the entire floor to that shelf with different warehouse bins or products that don’t need a shelf,” he says.
That approach eliminates unused airspace and makes the lowest tier both accessible and productive. In fast-paced warehouses, every second counts and workers need to reach products quickly without extra steps or equipment. The open bins create a flexible zone for fast-moving goods or seasonal items, while forklifts can still access the upper racks without interference.
“It’s basically multi-use,” Beckerman says. “These smaller operations have to be scrappy and find ways to fit different products and different workflows into the same footprint.”
As storage strategies continue to evolve, companies are realizing that efficiency isn’t only about speed; it’s also about how every cubic foot is used. The renewed focus on lower-tier storage proves that even simple layout and container placement adjustments can add measurable efficiency without a major capital investment.
6. Reusability and regulation shape what’s next
Reusable packaging continues to evolve as companies balance sustainability with system performance. Herbert says more organizations want “higher levels of post-consumer recycled content” in their packaging without giving up strength or consistency.
“Companies are looking for more recycled content in their packaging,” she says, “and they’re also asking about how to enable totes with technology to better track or gain more data about the contents being shipped.”
Some of that data can track metrics like use cycles, temperature and handling. Smart containers give companies visibility into where products go and how long each tote lasts, helping them extend the life of reusable assets. At the same time, regulation is reshaping expectations. Herbert points to the new Packaging and Packaging Waste Regulation (PPWR), which sets goals to minimize packaging waste, improve recyclability and promote reuse, as one new issue that companies are watching.
“We’re seeing regulations like the PPWR that will eventually impact all companies shipping to and from European countries,” she says. The regulation is already influencing global planning. “Companies are looking to understand the legal requirements and deadlines so they can create packaging programs today that will set them up for success in the future.”
Green also sees sustainability as one of the biggest drivers shaping container design right now. He expects that trend to continue. MDI is testing new additives and alternative materials that reduce reliance on petroleum-based plastics while maintaining strength and consistency.
As more tote and container manufacturers take similar steps, Green believes the conversation around sustainability will shift from “what’s required” to “what’s possible.”
“Companies want solutions that last longer and perform better, but they also want to feel confident they’re making the right choice for the environment,” Green says. “That’s where this industry is headed.”
