Case Study: Bespoke Two-Tiered Reusable Box for Almac Pharmaceuticals

Client: Almac Pharmaceuticals

Sector: Medical & Scientific
Location: Global Operations, Headquartered in Northern Ireland

Overview

Almac Pharmaceuticals, a global leader in pharmaceutical development and manufacturing, approached ReusableBox.net with a packaging challenge. They needed a reliable, reusable solution for transporting sensitive eye drop products equipped with Escort Data Loggers, ensuring both product safety and logistical efficiency.

Challenge

Almac’s logistics team required a packaging solution that could:

• Securely hold Escort Loggers for temperature-sensitive eye drops

• Accommodate multiple units while maintaining order and protection

• Allow for easy return and reuse, in line with their sustainability initiatives

• Withstand repeated handling through global distribution networks

Standard off-the-shelf packaging was falling short, especially in maintaining product orientation and preventing movement in transit.

Our Solution

We designed and manufactured a custom two-tiered reusable box tailored to Almac’s specific product and handling needs:

Tier 1: Custom Foam Insert for Escort Loggers

• Precision-cut high-density foam to snugly fit and protect Escort Data Loggers

• Eye drop containers nestled individually to prevent damage or shifting

• Easy access design for efficient loading and unloading

Tier 2: Compartment for Boxed Items

• The second layer was engineered to hold boxed batches of the same products

• Rigid dividers and stabilisers ensured all items remained secure during transit

• Layered structure allowed easy separation of monitored and bulk product components

Material & Sustainability

• Durable plastic outer shell designed for long-term reuse

• Fully returnable packaging, reducing waste and improving carbon footprint

• Designed for easy cleaning and sanitisation between cycles

Results

• Improved Protection: The custom foam prevented movement, protecting sensitive equipment and maintaining calibration integrity.

• Streamlined Handling: Two-tier design simplified the packing process and product segregation.

• Cost Efficiency: Reusability reduced Almac’s need for single-use packaging, driving down long-term costs.

• Sustainability Win: The returnable nature of the boxes aligned with Almac’s green initiatives and reduced packaging waste significantly.

Testimonial

“The reusable solution provided by ReusableBox.net transformed the way we package and transport this product line. It’s secure, robust, and aligns with our ongoing sustainability goals.”
— Logistics Coordinator, Almac Pharmaceuticals