At five in the afternoon, some warehouse staff are already preparing to wrap up their work. However, one order still cannot be found. The items turn out to be hidden behind stacks of other containers, while several cardboard boxes on the lower shelves have started to bend due to moisture exposure. As a result, the team has to recount inventory and delay the shipment.
Situations like this show that warehouse storage is not just about having enough shelves. It also involves choosing the right containers and organizing inventory locations effectively. Using stackable warehouse storage boxes made from corrugated polypropylene (PP) sheets, such as ALVAboard Boxes, can help create a more organized warehouse storage system with water-resistant material that can be reused as long as the boxes remain in suitable condition.
Why Can Ordinary Cardboard Boxes Become a Problem in Warehouses?
Paper-based cardboard boxes are suitable for various storage applications, but their performance needs to be considered when they are exposed to moisture and stacking loads. When cardboard absorbs water, its structural strength can decrease, increasing the risk of bending or losing stability.
The CTU Code, a cargo transport unit packing guide developed by the International Maritime Organization (IMO), International Labour Organization (ILO), and United Nations Economic Commission for Europe (UNECE), explains that an increase in relative humidity from 40% to 95% can reduce cardboard strength by up to 75%. This figure refers to a reduction in material strength under specific conditions, not the percentage of warehouse goods that may be damaged. Further information is available in the CTU Code guidelines.
In warehouse environments, unstable stacks can disrupt workflows and increase safety risks. OSHA material storage guidelines emphasize the importance of arranging materials securely to prevent them from shifting, falling, or collapsing, while keeping aisles clear of obstructions.
For these reasons, storage container selection should take into account environmental conditions, product characteristics, rack load capacity, and inventory picking frequency.
Advantages of ALVAboard Boxes for Warehouse Racking Systems
ALVAboard Boxes are made from PP Corrugated Sheet, a hollow-structured polypropylene sheet material. This material is lightweight and water-resistant, making it an alternative for storage applications that require containers that do not readily absorb water, unlike paper-based materials.
The surface can be cleaned according to appropriate maintenance procedures. These properties make the boxes suitable for storing components, spare parts, and operational supplies that need to be organized systematically. Polypropylene material can also be reused and recycled through waste management channels that accept this type of material.
For stackable warehouse racking applications, box dimensions, design, and load capacity must be matched to the stored goods and rack specifications. Do not rely on the container’s shape alone to determine stacking safety. Testing and establishing load limits remain essential to maintaining stability during daily operations.
As a pioneer in developing PP Corrugated Sheet applications for various industrial needs, ALVAboard provides material solutions that can be tailored to storage requirements. More information about its products and applications is available on the official ALVAboard website.
With the right specifications, companies can develop storage systems that support operational quality standards. This aligns with ALVAboard’s brand positioning as a leading PP Board brand in Indonesia, focused on storage solutions for a wide range of industrial applications.
ALVAboard Boxes vs. Cardboard Boxes for Warehouse Storage
When choosing storage containers, companies need to consider material properties and operating conditions. ALVAboard Boxes made from PP are water-resistant, whereas paper-based cardboard can absorb water, potentially weakening when exposed to moisture. In terms of resistance to bending, ALVAboard Box performance still depends on the design and tested load capacity, while cardboard is also susceptible to strength loss under damp conditions.
Maintenance is another important consideration. ALVAboard Box surfaces can be cleaned according to the recommended procedures, whereas paper-based cardboard may suffer fiber damage when wet or worn. For inventory identification, ALVAboard Boxes can be designed with labels or color-coding systems that match the company’s inventory organization. Cardboard boxes can also be labeled, but container consistency and label durability should be considered based on operational requirements.
How to Organize Warehouse Racks and Prevent Boxes from Bending
The first step is to organize goods according to how frequently they are picked or replenished. Fast-moving items should be placed in easily accessible locations, while slower-moving inventory can be positioned according to the warehouse space plan. Clear location assignments help reduce search time and unnecessary walking for staff.
Next, match box dimensions to the size of the racks and stored goods. Use clear labels on easily visible sides or a color-coding system that the entire team understands. Ensure that labels are consistent with inventory records so staff do not need to open multiple containers to find the items they need.
Finally, establish stacking rules based on tested load capacities. Inspect boxes regularly, never exceed rack load limits, and keep aisles free of obstructions. Effective warehouse organization must be supported by safety procedures and routine inspections, not just by choosing the right containers.
A warehouse process improvement case study published in the International Journal of Productivity and Quality Management in 2023 reported an increase in productivity from 42 to 59 items per picker per hour following the implementation of comprehensive process improvement methods. This result is not a guarantee that every warehouse will achieve the same outcome, but it demonstrates the value of evaluating storage and order-picking workflows.
ALVAboard operates a production facility in Tangerang and provides PP Board solutions for a wide range of industrial applications. With various applications and customizable requirements, ALVAboard positions itself as Indonesia’s largest PP Board manufacturer and a trusted partner for industries seeking high-quality materials tailored to their application specifications. To explore available products, visit the ALVAboard Official Store on Shopee.
Discuss Your Warehouse Storage Box Requirements with ALVAboard
Every warehouse has different storage requirements, from rack dimensions and product types to inventory picking frequency. Choosing the right boxes for actual operating conditions can help create a more organized and manageable storage system.
Discuss your stackable warehouse storage box requirements and other warehouse storage solutions with the ALVAboard team via WhatsApp at +62 877-9310-2838, or click the Contact Us button below to discuss box dimensions, designs, and specifications and find a solution that suits your warehouse storage system.
