Mango case: custom reusable boxes for automated logistics efficiency

When Mango invested in a fully automated distribution centre, their packaging needed to evolve with it. The challenge was clear: create a reusable box that could integrate seamlessly into high-speed automated systems while improving operational efficiency.

DW Reusables was selected to co-develop a solution tailored to Mango’s logistics environment.

Mango’s previous boxes were not compatible with the requirements of their automated handling systems. Stable stacking was critical, but the existing solutions did not provide sufficient reliability, leading to inefficiencies in both packing and unpacking processes.

With the introduction of ‘goods-to-person’ picking systems, speed and precision became even more important. Mango’s distribution model is built around rapid turnaround, moving products from design to store within a very short timeframe. This required packaging that could support high-performance logistics without creating bottlenecks.

Standard solutions were not sufficient for this level of operational demand.

To meet these requirements, DW Reusables designed a custom reusable plastic box adapted specifically to Mango’s automated environment.

The box features a non-standard dimension of 625 x 425 mm, optimised for integration within the existing system. In addition, it includes a patented functionality that allows certain product flows to be handled directly from the box, reducing handling steps within the distribution process.

Beyond system compatibility, the design also focused on usability. Lightweight construction and ergonomic handles improve day-to-day handling for operators, while maintaining the structural strength required for automated stacking.

The new reusable boxes significantly improved operational performance within Mango’s distribution centre.

Stable stacking reduced errors and increased efficiency in automated handling. The ability to nest the boxes when empty, by rotating them 180 degrees, allows for up to 70% space savings in storage and return logistics.

From a sustainability perspective, the shift from single-use packaging to reusable boxes reduced packaging waste to a minimum. The boxes are made from durable, hygienic material that is easy to clean and designed for long-term use. At the end of their lifecycle, they are fully recyclable.

This combination of operational efficiency and circular use supports both Mango’s logistics performance and sustainability ambitions.

This project illustrates how DW Reusables approaches reusable packaging in complex environments.

By understanding the full logistics flow, from automation systems to operator handling, we design solutions that integrate seamlessly into existing operations. Our in-house design and engineering capabilities allow us to adapt dimensions, functionalities, and materials to specific use cases rather than relying on standard products.

The result is packaging that not only fits the system, but actively improves it.

Mango is a global fashion company headquartered in Spain, with stores worldwide. Its 250,000 m² distribution centre in Barcelona is one of the most advanced logistics platforms in the industry, capable of processing up to 75,000 units per hour using state-of-the-art automation technologies.

We combine technical expertise, industry knowledge, and genuine collaboration to create reusable packaging solutions that perform in your operations today and evolve with your needs tomorrow.