Reusable Box

At Reusable Box, we’re always looking for ways to push quality, speed, and sustainability forward. That’s why we’ve just added the DYSS X7 Digital Cutting System to our workshop — and it’s a game-changer for custom packaging.

Whether we’re building precision transport boxes for medical equipment or developing collapsible solutions for high-end scale models, our new cutting machine means even more accuracy, flexibility, and efficiency for our clients.

What Is the DYSS X7?

The DYSS X7 is a versatile digital cutting system, designed to process a wide variety of materials with razor-sharp accuracy — from corrugated plastic and foam inserts to cardboard, vinyl, and beyond.

It uses advanced routing, kiss-cutting, and creasing tools, allowing us to create complex parts, internal foam layouts, and folding designs faster and cleaner than ever before.

Why It Matters to Our Clients

Here’s how this upgrade benefits the businesses we serve:

• Faster Turnarounds – Quicker setup and production mean we can meet tighter deadlines

• Unmatched Precision – Every cut, every slot, every panel edge is clean and perfectly aligned

• Material Efficiency – Less waste, better yield, and smarter layout planning

• Prototyping Made Easy – We can now quickly mock up sample designs before full production

• Complex Inserts? No Problem. – Intricate foam layouts for delicate items like instruments, electronics or collector items are now easier to produce at scale

Stronger Capability, Same Custom Focus

This machine strengthens what we already do best: bespoke, sustainable, reusable packaging.

From one-off custom builds to full repeatable runs, the DYSS X7 allows us to stay lean, flexible, and fiercely quality-driven — whether we’re producing 5 boxes or 500.

📦 Have a tricky product to ship or store?
We’re now better equipped than ever to design your perfect solution.

📩 Get in touch and let’s build something clever.

When people think of reusable packaging, they often focus on the external features — the durability of the box, its stackability, or the environmental benefits. But inside every great box is an often overlooked, yet essential component: the foam insert.

At Reusable Box, we design every insert with precision, purpose, and protection in mind.

🔍 What Are Foam Inserts and Why Do They Matter?

Foam inserts are custom-cut pieces of high-density foam placed inside your reusable box to house and protect your products. Think of them as tailored compartments that securely cradle each item, preventing movement, damage, and mishandling during transit.

They’re especially critical in sectors like:

• Pharmaceutical and medical packaging (e.g. Escort Data Loggers)

• Electronics and instrumentation

• Military-grade or aerospace components

• Film & TV kit transport

✅ The Reusable Box Approach to Foam Design

Every insert we create is made to match your product’s exact dimensions. That means:

• No excess movement

• Faster packing and unpacking

• Reduced risk of damage

• More consistent workflows across your supply chain

We can also design:

• Multi-tiered inserts

• Compartments for cables, accessories or documents

• Colour-coded foam for visual identification

• Water-resistant or antistatic foams, depending on application

♻️ Why Custom Foam + Reusable Box = Long-Term Gains

A well-designed foam insert extends the life of your packaging — and your product. Combined with our reusable outer boxes, the insert plays a big role in:

• Minimising product damage

• Reducing the need for replacement parts or reshipments

• Lowering packaging waste

• Creating a consistently professional appearance for your brand

🛠️ Real Example: Almac Pharmaceuticals

We recently helped Almac transport sensitive Escort Data Loggers using a custom two-tier reusable box. The top layer featured precision-cut foam inserts to secure the loggers, while the bottom layer housed their boxed units. The result? Faster, safer packing, and zero damage in transit.

📩 Ready for Your Own Insert?

If you’re shipping high-value, high-risk, or high-volume products, don’t settle for generic packaging. Let’s design something that protects what matters most.

At Reusable Box, we don’t just make packaging — we solve packaging problems. To better understand what matters most to our clients and the wider market, we recently conducted a large-scale insights campaign targeting procurement managers, logistics coordinators, and packaging decision-makers across multiple industries.

From healthcare and aerospace to electronics, events, and film production, one thing became clear: businesses are evolving their packaging priorities.

So, what’s at the top of the list in 2025?

📊 The Results Are In:

Here’s how our respondents ranked the most important factors in their packaging decisions:

• ♻️ Sustainability – 42%

• 🛡️ Durability – 31%

• 💷 Cost – 17%

• ⚖️ Weight – 10%

♻️ Sustainability Takes the Lead (42%)

No surprise here. With growing ESG commitments, green supply chain goals, and rising pressure from stakeholders, sustainability has taken the top spot.

Reusable packaging offers a powerful solution:

• Fewer single-use materials

• Less waste generated over time

• Longer product lifecycle

• Fully recyclable internal components (e.g. foam inserts)

It’s clear that businesses are looking beyond the first journey — they’re designing for the long haul.

🛡️ Durability Comes in Second (31%)

Durability matters more than ever in industries with complex handling processes. From rugged transport environments to long-term storage, packaging that protects — and keeps protecting — is essential.

That’s why Reusable Box focuses on:

• Sturdy box construction using heavy-duty materials

• Impact-resistant foam inserts

• Lockable lids and stackable designs

When packaging gets reused hundreds of times without failing, it becomes more than packaging — it becomes part of your workflow.

💷 Cost Still Matters (17%)

While not the top concern, cost is always part of the equation — especially in high-volume operations. But many respondents acknowledged that long-term savings are more valuable than initial cost cuts.

Reusable Box offers ROI-friendly solutions by:

• Reducing the need for repurchasing

• Lowering product damage and returns

• Streamlining loading and transport times

• Supporting tax and compliance goals related to waste reduction

⚖️ Weight Is a Factor, But Not a Deal-Breaker (10%)

Weight matters most in air freight or manual handling operations. Lighter solutions are sometimes preferable, but many customers told us they’d happily accept added weight for more durability and environmental gain.

That’s why we work to strike the balance: keeping our boxes strong but efficient, without compromising performance.

🔍 What This Means for Your Business

If you’re still relying on single-use or flimsy packaging solutions, you’re not aligned with what the market values most. Customers, stakeholders, and your team all benefit from smarter, reusable designs.

At Reusable Box, we:

• Tailor packaging to your product

• Design with industry-specific demands in mind

• Offer expert advice on reusability, sustainability and logistics

• Manufacture right here in the UK

📞 Want Packaging That Ticks All the Boxes?

Let’s create a packaging system that protects your product, your reputation, and your planet.

👉 Talk to us now or explore our solutions at www.reusablebox.net