Building Three Custom Reusable Boxes for Almac Pharma

When Almac Pharmaceuticals approached us, the brief was intentionally loose. They had already used a previous version of our reusable box on site and loved how robust and reliable it was for day to day movement. This time they wanted something more versatile. Instead of one box for one job, they wanted a small family of reusable boxes that could support a wide range of internal transfers across departments, buildings and specialised work areas.

So we designed three different sized boxes with matching foam cushioned inserts for general purpose use throughout their facility.

A Modular Set for Every Task

Pharmaceutical workflows never stand still. Instruments move between labs, testing areas, offices, cleanrooms and storage locations all day long. While the items can change, the demands stay the same: protect the contents, keep everything traceable and make transfers as efficient as possible.

Our solution was to create:

• A small case for compact instruments, handheld devices and delicate items

• A medium case for mid sized equipment and testing components

• A large case built to handle bulkier or multi part items without compromising protection or weight

Each size follows the same structural design so staff can immediately recognise and use them in any department.

Foam Cushioned Inserts for a Flexible Payload

Because Almac needed these boxes for general purpose use, the inserts had to work for many different instruments. Instead of fixed cut outs, we engineered a foam system that gives protection without limiting the shape or size of the payload.

Our 30kg/m³ foam in flexible thicknesses creates a cushioned environment that keeps sensitive items safe during hand carry transfers or trolley movement between buildings.

Security Built Into the Design

Moving instruments inside a busy pharmaceutical environment means security and chain of custody is crucial. Each box includes dedicated locking points for cable ties, allowing staff to seal units quickly and clearly before transfer.

Once the box reaches its destination, the receiving team can confirm that the tie is intact, remove it and continue their workflow with confidence.

Durable and Reusable Across Facilities

All three boxes are built using our heavy duty corrugated polypropylene. It is lightweight, robust and totally water resistant so it stands up to the exact kind of internal transfers pharmaceutical teams carry out every day. From lab corridors to external walkways between buildings, these boxes are designed to last year after year.

A Simple Brief Turned Into a Complete Multi Box Solution

Almac gave us the freedom to design something practical and universal, and the result is a family of reusable boxes that slot seamlessly into their day to day processes. Whether the task is small, medium or large, they now have a consistent protective system that boosts efficiency and safety across their site.

If your organisation needs a similar internal movement solution or a customised version for a specialist workflow, Reusable Box can design it from the ground up.