Zara case: reusable totes designed for high-speed automated distribution
When Zara upgraded its distribution centre with advanced automation systems, its packaging needed to evolve accordingly. The challenge was to develop reusable totes that could perform reliably within a high-speed, automated logistics environment.
DW Reusables was selected to design a solution that would integrate seamlessly into Zara’s operations.
Packaging challenges in automated fulfilment systems
Zara’s distribution model is built around speed and responsiveness. Products move quickly from design to store, supported by a highly efficient supply chain and frequent deliveries.
With the introduction of ‘goods-to-person’ picking systems, operational efficiency increased significantly. In this setup, products are automatically brought to operators, reducing movement and accelerating order fulfilment.
However, the totes previously in use were not suited to this new system. They lacked the stacking stability required for automated handling, creating inefficiencies and limiting the performance of the distribution process.
In high-volume automated environments, even small instabilities can lead to delays.
A custom tote designed for system integration
To meet these requirements, DW Reusables developed a reusable plastic tote tailored specifically to Zara’s automated distribution systems.
The design features a non-standard dimension of approximately 650 x 450 mm, optimised for integration with the picking equipment. This ensures stable stacking and smooth handling throughout the automated process.
Beyond system compatibility, the tote was engineered for daily operational use. Its lightweight construction and ergonomic handles improve usability for operators, while maintaining the strength required for intensive logistics flows.
The result: improved efficiency and reduced packaging waste
The introduction of the new reusable totes enabled Zara to fully leverage its automated distribution system.
Stable stacking improved reliability within the picking process, supporting faster and more consistent order fulfilment. When empty, the totes can be rotated 180 degrees to become nestable, reducing storage and return logistics volume by up to 70%.
By replacing single-use packaging with reusable totes, Zara significantly reduced packaging waste. The totes are made from durable, hygienic materials that are 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 packaging supports both performance and sustainability goals.
Why this approach works
This project highlights how DW Reusables develops packaging solutions for complex logistics environments.
By analysing how systems operate in practice, from automation to manual handling, we design solutions that integrate seamlessly into existing workflows. Our in-house design capabilities allow us to adapt dimensions and functionalities to specific requirements, rather than relying on standard products.
The result is packaging that not only fits the system, but enhances its performance.
About Zara
Zara is a global fashion brand and part of the Inditex group. Known for its highly responsive supply chain, Zara delivers new products to stores twice a week. Its centralised distribution centre in Spain processes all products, enabling rapid turnaround from design to retail.
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