FedEx rolls out scalable reusable packaging for B2B shippers

24 / 05 / 2026

By Marwa Nassar - -

FedEx has launched a new reusable packaging solution for business-to-business (B2B) shippers, as the logistics giant looks to help retailers lower packaging costs and reduce environmental impact across supply chains.

The system was developed in collaboration with Returnity and features a FedEx-specific reusable box designed to integrate directly into the company’s existing logistics network.

Reusable packaging designed for scalable logistics:

The new packaging solution is aimed primarily at B2B soft-goods shippers and allows customers to transition from traditional corrugated boxes to reusable packaging formats without incurring the handling fees often associated with alternative shipping containers.

“In collaboration with Returnity, we have created the first scalable, reusable box solution for B2B customers, which is especially useful for our soft-goods shippers,” said Neil Gibson.

“By pairing Returnity’s durable, easy-to-integrate packaging with our global network, we’re helping retailers unlock meaningful cost savings while reducing environmental impact, all without sacrificing speed or reliability. This new solution supports our vision to make supply chains smarter for everyone,” he added.

Closed-loop supply chains drive efficiency gains:

While reusable packaging has existed for years, large-scale adoption within parcel delivery networks has often been limited by cost, operational complexity, and compatibility with existing logistics systems.

FedEx said the new box was engineered to address those challenges through a durable, collapsible, and automation-friendly design that works within current FedEx infrastructure.

The solution is designed for closed-loop shipping environments such as fulfillment centers, retail replenishment networks, and field service operations, where product returns are predictable and controlled.

Each reusable box can support up to 50 shipment cycles and carry up to 50 pounds of goods.

According to FedEx, the packaging format can reduce packaging costs by as much as 30% per shipping cycle and lower carbon emissions by between 64% and 88% compared with single-use corrugated boxes under typical operating conditions.

Pilot program tested across North America:

The reusable packaging system has already been piloted with multiple FedEx B2B customers across North America, including in fulfillment-to-store replenishment, internal transfers, and reverse logistics operations.

During the pilot phase, participating shippers reported improvements in labor efficiency, faster unpacking and restocking, better backroom organization, and lower product damage rates.

“FedEx made reuse make sense by building the business case, doing the work, and creating a model for how circular logistics can succeed at scale,” said Mike Newman.

Expansion planned beyond the US:

The reusable packaging system is currently available to FedEx customers in the United States, with the company planning future expansion into Australia and Europe.

The launch forms part of FedEx’s broader sustainability strategy, which includes a target to achieve carbon-neutral operations globally by 2040.