How the Cost-Per-Trip Model Works
Cost per trip is the only basis on which reusable and single-use packaging can be compared honestly. Reusable packaging carries a high purchase price amortized across many cycles plus recurring wash, return freight and shrink. Single-use packaging carries a low unit price paid on every single shipment, plus disposal.
The formula
Reusable = (unit price ÷ expected trips) + wash + return freight + (unit price × loss rate ÷ trips per year)
Single-use = box cost + disposal
The two variables that decide the result
- Expected trips. Model from observed cycle time, not catalog service life. Dwell at the receiving plant is where programs lose cycle velocity.
- Loss rate. Above roughly 10% annual shrink, ownership economics deteriorate quickly and asset control has to be solved before the fleet grows.
Full methodology, including when reusables do not win, is in our returnable packaging TCO guide.