Retailers ditch cardboard with ‘The Last Box’ for reusable packaging revolution
A reusable packaging solution called 'The Last Box' is now being used by many retailers to cut waste and streamline operations. The system, launched in April 2023, replaces single-use cardboard in high-volume locations like distribution centers and stores. Over 100,000 units have already been deployed, with expectations to remove nearly four million cardboard boxes from circulation within a year.
Returnity, the company behind 'The Last Box', designed it to handle repeated use across multiple stages of retail operations. Each container is built to eliminate around 50 cardboard boxes and 300 feet of packing tape over its lifespan. The goal was to address inefficiencies in backroom fulfillment, where spaces originally meant for storage now handle e-commerce returns, same-day pickups, and seasonal surges.
Retailers adopting the system have reported faster processing, less product damage, and better inventory control. Mike Newman, CEO of Returnity, noted that backrooms were never intended as fulfillment hubs but now face constant pressure from tight deadlines and limited space. Locations using personal-vehicle delivery networks—where space and speed are critical—are seeing the most benefit. The system also supports hybrid fulfillment models, helping retailers shift toward circular packaging systems. By reducing reliance on single-use materials, 'The Last Box' aims to cut waste in thousands of high-volume sites while improving operational efficiency.
With over 100,000 units already in use, 'The Last Box' is set to replace nearly four million cardboard boxes in its first year. Retailers using the system have seen time savings, less waste, and improved handling of goods. The shift reflects broader industry efforts to adapt backroom spaces for modern fulfillment demands.
