Top 7 Tools for Tracking Reusable Packaging Returns

Reusable packaging is great for reducing waste, but tracking it effectively is a challenge. Businesses lose $800M to $1.5B annually due to missing pallets, crates, and containers. Manual methods like spreadsheets fail to provide real-time visibility, leading to inefficiencies, over-purchasing, and production delays. With regulations like the EU’s PPWR requiring 40% reusable transport packaging by 2030, advanced tracking systems are now essential.

Here are 7 tools designed to simplify reusable packaging tracking, reduce losses, and improve operations:

• Reusables.com: Uses RFID/QR codes and Smart Return Bins for real-time tracking, achieving return rates as high as 99.6%.
• TrackOnline: Cloud-based SaaS platform with RFID/QR integration for centralized tracking and automated alerts.
• ORBIS SmartTrak: Combines RFID and QR codes for inventory management, reducing packaging emergencies and costs.
• Alpega: Tracks individual containers with serial numbers and integrates with ERP systems for global supply chain visibility.
• Wiliot: Uses battery-free Bluetooth sensors for automated, real-time tracking, cutting shrinkage by up to 50%.
• UNDO Software: Offers Digital Product Passports and automates returns, maintenance, and compliance reporting.
• Vytal: QR-based deposit-free system supporting up to 200 uses per container, reducing single-use waste.

These tools leverage technologies like IoT, RFID, and QR codes to provide real-time insights, cut losses, and meet regulatory requirements. They also support measurable sustainability goals by maximizing reuse cycles and reducing waste.

Quick Comparison:

Tool	Tracking Method	Key Features	Best For
Reusables.com	RFID/QR codes, Smart Bins	Automated returns, real-time data	High return rates and user-friendly systems
TrackOnline	RFID/QR, cloud-based platform	Centralized tracking, automated alerts	Complex logistics with multiple partners
ORBIS SmartTrak	RFID/QR codes	Inventory management, cost reduction	Avoiding packaging emergencies
Alpega	Serial numbers, ERP integration	Global supply chain visibility	Large-scale operations needing precise tracking
Wiliot	Bluetooth IoT sensors	Scan-free tracking, shrinkage reduction	Low-maintenance, automated systems
UNDO Software	Digital Product Passports, QR codes	Automated returns, compliance reporting	EU regulation compliance
Vytal	QR codes	Deposit-free, pay-per-use model	Reducing single-use waste

These tools transform reusable packaging from a liability into a manageable asset, helping businesses save money and comply with regulations.

1. Reusables.com Platform

Real-Time Tracking and Visibility

Reusables.com employs a dual tracking system that assigns a digital identity to every container using either a QR code or an embedded RFID chip. Through its real-time dashboard, operators gain access to critical data such as inventory levels, usage patterns, return rates, and bin fullness - all without the hassle of manual counting.

The platform's Smart Return Bins are operational 24/7, automatically registering returned containers and sending alerts when bins need servicing. For example, Simon Fraser University's Mackenzie Café achieved a 99.63% return rate across 18,700+ reuses in June 2025 using this system. Similarly, the University of Guelph processed over 500,000 reuses annually with a 99% return rate. This level of visibility, combined with RFID/QR integration, ensures smooth user experiences and efficient operations.

Integration with RFID/QR Technology

Reusables.com introduces its patented Tap-to-Reuse™ technology, simplifying the checkout process by eliminating the need for app downloads or upfront deposits. Users can tap their credit card, student ID, or mobile wallet to check out a container. The system links the RFID or QR tag to the user's account automatically, ensuring accountability and sending reminders for unreturned items.

"By making the checkout process as simple as a tap of a card, you remove the initial friction".

In October 2025, Pomona College showcased the effectiveness of this technology by integrating it with the Transact Campus Student ID system. The result? 70,000 reuses with a 98.2% return rate, saving over $20,000 annually. This streamlined process not only enhances user convenience but also reduces operational costs.

Logistics Optimization and Cost Savings

The platform helps businesses cut down on single-use packaging costs and labor expenses. For instance, Hollyburn Country Club saw a return on investment within just 2 months, saving between 8,000 and 10,000 paper cups and plastic lids. Additionally, the Bintelligence feature optimizes collection routes by monitoring bin fullness.

Data from the platform reveals that 100% of customers find logistics easier to manage with Reusables, while 92% of users feel it simplifies choosing sustainable options. The platform is designed for rapid deployment, transitioning from an initial discovery call to full implementation in 4 weeks or less. Businesses can choose between leasing, purchasing, or retrofitting their existing inventory with tracking labels.

Support for ESG Metrics and Sustainability

Reusables.com automatically generates impact reports that track environmental benefits, such as the number of single-use items diverted from landfills, reductions in carbon emissions, and water conservation. These reports provide a clear return on investment and demonstrate compliance with regulations. The platform’s ESG dashboard translates usage data into measurable outcomes, including CO2e and water savings, helping businesses turn their sustainability goals into actionable achievements.

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2. TrackOnline Software

Real-Time Tracking and Visibility

TrackOnline is a cloud-based SaaS platform designed to simplify the management and tracking of reusable packaging, such as crates, pallets, and roll containers. It consolidates data into one central hub, giving businesses and their supply chain partners a single source of truth. This eliminates the need for messy spreadsheets, offering instant visibility into asset balances across customers and suppliers, along with precise location tracking.

The platform monitors key performance metrics like cycle times, return rates, and asset losses, equipping managers with actionable insights to prevent costly bottlenecks. Automated alerts notify teams when assets are held too long or when shortages arise. This proactive approach improves supply chain efficiency. Through a customer portal, partners can access real-time balance information, reducing disputes and cutting down on manual back-and-forth communication.

Integration with RFID/QR Technology

TrackOnline integrates effortlessly with RFID, QR codes, barcode scanners, and IoT sensors, streamlining the tracking and registration of reusable packaging. A partnership with Sensolus enhances this functionality by enabling sensor-based tracking for non-powered assets. This integration reduces manual data entry by up to 80%.

"With Sensolus we have found a reliable partner for our customers who want to track their reusable packaging uniquely using smart hardware. Thanks to this collaboration, our customers can get started with real-time tracking within TrackOnline right away." - Toon de Jong, CEO, TrackOnline

The platform ensures seamless connectivity with existing systems like ERP, TMS, and WMS, maintaining consistent data across the organization. This is especially crucial as the EU's Packaging and Packaging Waste Regulation (PPWR) requires 40% of transport packaging to be reusable by 2030. With transparent reporting and data integration, businesses can stay ahead of compliance demands while improving operational workflows.

Logistics Optimization and Cost Savings

By automating settlements and communication with partners, TrackOnline reduces the need for surplus packaging. Companies using the platform have reported a 50% reduction in replacement costs for lost or missing assets. The software identifies when assets remain idle at customer sites longer than agreed, helping businesses optimize collection schedules and boost utilization rates.

TrackOnline is pooler-independent, meaning it can manage assets from various pooling providers or a company’s private fleet, all within one system. New users can explore its features with a 30-day free trial. Beyond cost savings, the platform also supports detailed sustainability reporting.

Support for ESG Metrics and Sustainability

TrackOnline provides reliable data for audits and compliance reporting, helping businesses meet regulatory requirements and back up their sustainability claims. By optimizing reuse cycles, the platform can cut CO2 emissions by 30%. Its transparent reporting tools align with regulations like the PPWR, which demand verifiable data on reusable packaging performance. These metrics not only ensure compliance but also enable businesses to implement effective circular supply chain strategies.

3. ORBIS SmartTrak

Real-Time Tracking and Visibility

ORBIS SmartTrak is asset management software that keeps tabs on reusable packaging as it moves through the global supply chain. Through a secure online portal, users can track their empty packaging inventory, including current stock levels, arrival times, and items in transit. This helps avoid both stock shortages and overstocking.

The platform also provides proactive notifications and automated reports about packaging events, helping teams stay ahead of potential disruptions. With its strategic planning module, SmartTrak360, companies can make real-time decisions about replenishment and asset movement to meet just-in-time needs.

"With ORBIS SmartTrak, companies are able to replenish packaging based on actual demand, eliminate manufacturing disruptions and prevent transportation expedites associated with packaging stock-outs".

By integrating RFID and QR code technology, the system converts real-time tracking data into actionable insights.

Integration with RFID/QR Technology

SmartTrak leverages RFID tags and QR codes to turn raw data into meaningful business intelligence. This integration simplifies operations and ensures the accuracy of tracking data. RFID readers can scan hundreds of tagged containers in specific zones at once, eliminating the need for manual scanning. Meanwhile, QR codes offer a durable and cost-effective alternative for manual scans at key transit points, with better data capacity and error correction than traditional barcodes.

This automated data capture creates a single source of truth for tracking reusable assets and reduces errors caused by manual data entry. ORBIS has partnered with Today IT to enhance these capabilities, with their AVALANCHE platform now supporting over 20,000 users in Europe and the United States.

Logistics Optimization and Cost Savings

SmartTrak helps companies cut costs by reducing premium freight expenses linked to packaging emergencies. It optimizes the use of return trucks and ensures replenishment is based on demand, avoiding the need for costly expedited shipments.

"We've seen a 30% average reduction in dwell time, for example, by discovering totes sitting in semi-trailers at a supplier who was waiting to fill the trailer before returning the packaging".

This level of visibility helps businesses pinpoint bottlenecks and make process improvements.

ORBIS also provides flexible financial options, such as per-trip pooling programs that eliminate the need for large upfront investments, as well as leasing and rental choices. Additionally, the platform integrates with ORBIS Reusable Packaging Management (RPM) services, which handle sorting, cleaning, and repairing assets, offering a complete end-to-end solution. These efficiencies not only save money but also align with ORBIS's focus on sustainability.

Support for ESG Metrics and Sustainability

SmartTrak supports circular economy initiatives by tracking usage cycles and identifying assets in need of maintenance, which extends their lifespan and reduces the demand for new containers. ORBIS uses life-cycle assessments to help customers measure the environmental benefits of switching from single-use to reusable packaging.

Through the "Recycle with ORBIS" program, end-of-life plastic packaging is recovered, reprocessed, and turned into new products, earning customers credits for future programs. This closed-loop system ensures responsible disposal and supports sustainability claims while meeting regulatory standards.

4. Alpega Reusable Packaging Management

Real-Time Tracking and Visibility

Alpega's centralized control tower provides real-time tracking of reusable packaging across global supply chains. What makes it stand out is its ability to track individual containers using serial numbers, RFID, and barcodes. It also integrates with MultiParcel, offering last-mile visibility across hundreds of Courier Express Parcel (CEP) providers. This detailed tracking helps pinpoint partners holding onto containers for too long, avoiding capital lockup and disruptions in replenishment cycles.

The platform seamlessly integrates with ERP systems like SAP, ensuring smooth data exchange between existing infrastructure and the packaging management module. For instance, MAN Truck & Bus AG adopted this centralized system under Heiko Kayser, Head of Global Transportation & Containers. This shift reduced their container inventory and gave them real-time insights into their supply chain.

"The ability to quickly connect with all of our suppliers is my personal favorite - in the past we spent a great deal of time coordinating with all of the individual parties involved."

• Heiko Kayser, Head of Global Transportation & Containers, MAN

This high level of connectivity paves the way for better logistics and improved financial transparency.

Logistics Optimization and Cost Savings

Alpega automates inventory monitoring using push-and-pull controls, helping businesses maintain optimal stock levels and avoid costly emergency shipments. Its predictive analytics use historical data to forecast future packaging needs, ensuring you're prepared for demand spikes without overstocking.

The platform also includes a packaging fee settlement module to track all costs and fees tied to container movement. This transparency can turn packaging pools into profit centers. By streamlining processes and reducing manual tasks, companies using Alpega's TMS solutions have reported over 80% savings in process costs and up to 8% savings on freight expenses through better routing.

But Alpega's benefits go beyond cost efficiency - it also supports sustainability efforts.

Support for ESG Metrics and Sustainability

Alpega promotes the shift to a circular economy by replacing single-use materials with durable, returnable packaging. This change reduces greenhouse gas emissions and aligns with 2026 sustainability compliance requirements. The platform tracks environmental impact data, offering valuable insights for ESG reporting and regulatory needs.

"Alpega's RPM is both environmentally friendly and cost‑efficient. The solution can reduce GHGs, as it replaces the need for so much packaging material, energy and labor."

• Alpega Group

With serialized tracking, Alpega extends the lifecycle of containers, cutting down on replacement costs and waste. Its integration of sustainability metrics into logistics operations simplifies the process of meeting environmental goals. This approach not only supports greener supply chains but also aligns with the demands of streamlined e-commerce fulfillment and circular supply chain models.

5. Wiliot RTP Tracking System

Integration with RFID/QR Technology

Wiliot steps away from traditional RFID or QR code systems by introducing battery-free Bluetooth sensors called IoT Pixels. These small tags gather energy from ambient radio waves, eliminating the need for batteries or charging. Unlike barcodes that require manual scans or RFID systems that demand expensive infrastructure, Wiliot uses affordable, off-the-shelf Bluetooth bridges to create a seamless tracking network.

What sets this system apart is its scan-free operation. Assets automatically report their location and status, while the Wiliot Cloud processes over 100 times more data than standard RFID or barcode systems. This setup provides a strong framework for real-time operational insights.

Real-Time Tracking and Visibility

With this technology, Wiliot achieves 95–99% asset visibility within just 15 minutes. Beyond simple location tracking, IoT Pixels monitor key conditions like temperature, humidity, and handling in real time. The platform uses AI to analyze millions of data points, issuing automated alerts for potential problems such as delays, mis-shipments, or temperature changes.

In 2024, Royal Mail adopted this system, tagging 850,000 wheeled roll cages across nearly 5,000 sites. The enhanced visibility allowed them to improve vehicle usage and save millions of dollars by avoiding unnecessary asset purchases.

"There will be no assumptions or manual checks required anymore, with visibility of both an individual item and the entire network flow. We can now focus in on minimizing disruption and ensuring the most accurate on-time deliveries."

• Alistair Cochrane, Chief Operating Officer, Royal Mail

Logistics Optimization and Cost Savings

Wiliot’s tracking capabilities address a common challenge in distribution: the loss of 10–15% of delivery assets annually due to shrinkage. The system can cut this loss by up to 50%. Large-scale deployments have shown annual savings of $10 million or more from reduced shrinkage and fleet optimization. Additionally, infrastructure costs are 5–10 times lower compared to traditional RFID solutions.

Real-time tracking also automates key processes like loading validation to avoid mis-shipments and identifies underused vehicles for better truckload management. Companies using Wiliot have reduced fleet sizes by 30–40%, eliminating the need for "just-in-case" over-purchasing. Automated cycle counts further boost inventory accuracy to over 99%. These efficiencies not only save money but also help lower the carbon footprint.

Support for ESG Metrics and Sustainability

Wiliot’s system adds another layer of value by offering a digital audit trail for reuse cycles. This makes it easier to measure carbon savings and meet ESG reporting standards. Since transportation accounts for 70–80% of reuse costs per rotation, optimizing routes and vehicle usage has a direct impact on reducing emissions. The system also ensures reusable packaging programs reach at least 20 rotations - the tipping point where they outperform single-use options both financially and environmentally.

In addition, Wiliot supports compliance with FSMA Rule 204 and pharmaceutical GMP by maintaining detailed records of handling and environmental conditions.

6. UNDO Software

Integration with RFID/QR Technology

UNDO Software uses RFID and QR technology to give each reusable packaging item a distinct digital identity, or "digital twin." These tags act as entry points for data, allowing the platform to track every item as it moves through distribution, use, and return. The system works with a variety of hardware, helping businesses choose and implement the best tagging solutions for their needs.

By automating workflows, UNDO assigns statuses and initiates actions throughout an asset's lifecycle. It also tracks details like usage, repairs, and cleaning histories for over 1,000,000 products.

Real-Time Tracking and Visibility

With item-level monitoring, the platform provides live updates on an asset's status - whether it's in use, returned, inspected, or due for repair. This comprehensive traceability creates a full audit trail for each asset, reducing losses and extending their lifespan. Digital Product Passports (DPP) further enhance transparency by giving all supply chain stakeholders access to relevant data, breaking down silos.

This detailed tracking not only improves oversight but also supports cost savings through automated returns and maintenance.

Logistics Optimization and Cost Savings

UNDO simplifies returns with automated deposit and loyalty programs, encouraging customers to return packaging by offering financial incentives. The platform integrates smoothly with ERP and WMS systems like SAP, Odoo, and Salesforce, eliminating manual data entry errors and ensuring efficient operations.

By logging inspections automatically and flagging potential issues, UNDO shifts maintenance from reactive to proactive. This approach helps extend asset lifespans and cuts down on unnecessary replacement expenses.

For businesses exploring reusable packaging programs, UNDO offers a free starter package with no hidden fees, making it an accessible option.

Support for ESG Metrics and Sustainability

Beyond operational efficiency, UNDO helps businesses meet sustainability goals. It aids compliance with the EU's Packaging and Packaging Waste Regulation (PPWR), which aims to boost the use of reusable transport packaging by 2030. Automated reporting tools and Digital Product Passports provide the necessary audit trails for regulatory adherence, while legally binding e-signatures enhance security and trust in circular business models.

For companies adopting circular e-commerce strategies, UNDO offers customizable templates designed for rental and second-hand storefronts. These templates support the shift from traditional "take-make-waste" systems to circular "Products-as-a-Service" models, making it easier for brands to embrace sustainable practices.

7. Vytal Global Platform

Integration with QR Technology

Vytal uses laser-engraved QR codes to assign unique digital IDs to reusable containers, enabling a deposit-free system. By incorporating the Scandit Barcode Scanner SDK, any smartphone can function as a high-performance scanner, ensuring seamless tracking of containers throughout their lifecycle. As Dr. Josephine Kreische, Managing Director at Vytal, puts it:

"The QR code and Scandit's high performance scanning play a vital role in our deposit-free reusables solution. Our busy restaurant partners can scan containers with assured speed and accuracy on any smartphone."

This system creates a comprehensive digital trail for each container, allowing it to be tracked through as many as 200 uses.

Real-Time Tracking and Visibility

The platform allows customers to borrow containers for a 14-day period before fees are applied. Every scan updates the system in real time, providing precise location data and tracking the container's journey across various locations. This real-time visibility helps partners monitor inventory and analyze usage trends. As of December 2022, this system has helped eliminate the need for over 5 million single-use containers, benefiting a network of more than 6,000 partners across 10+ countries.

Logistics Optimization and Cost Savings

Vytal replaces the need for upfront container purchases with a pay-per-use rental model. The platform also handles storage, logistics, cleaning, and distribution, leveraging real-time data to identify popular drop-off points.

For example, during the OMR Festival in May 2024, Vytal's system was used to manage food and beverage packaging across the event. Marius Mohn, Teamlead Gastro at OMR, shared:

"With Vytal, we have found a flexible, digital reuse solution that has enabled us to make the F&B area at the OMR Festival 2024 more digital and sustainable."

Similarly, the Berlinale press center adopted Vytal's deposit-free system to replace single-use cups, showcasing the platform's ability to support both everyday restaurant operations and large-scale events.

Support for ESG Metrics and Sustainability

The platform includes built-in environmental reporting tools that measure reductions in disposable packaging waste. This feature has earned Vytal accolades such as the German Sustainability Award, the 18/1 Award 2023, and the Blue Angel eco-label. By tracking containers through up to 200 uses before recycling, Vytal offers a measurable alternative to single-use packaging.

With its advanced QR technology and detailed sustainability metrics, Vytal stands out as a key player in efficient, eco-friendly reusable packaging management.

Tracking Reusable Packaging Containers at Scale

Feature Comparison Table

Choosing the right tracking tool depends on your logistics setup, container volume, and integration requirements. Below is a table comparing the key features and ideal use cases of leading tracking tools.

Tool	Tracking Method	Key Strengths	Best For	Scalability
TrackOnline Software	RFID, Barcodes, QR Codes	Cloud-based platform managing physical, financial, and administrative flows with ERP/TMS integration	Complex reusable packaging logistics involving multiple stakeholders	High
Wiliot RTP Tracking System	Ambient IoT (battery-free, Bluetooth-enabled tags)	No battery maintenance and continuous real-time visibility without manual scanning	Large-scale operations in need of automated, low-maintenance tracking	Very High
UNDO Software	Digital Product Passports (DPP), QR Codes	Compliance with EU PPWR and digital identity for packaging	Companies preparing for EU packaging regulations requiring 40% reusable transport packaging by 2030	Medium to High

Each tracking method has its strengths. Label-based systems like Barcodes and QR Codes are ideal for closed-loop, low-complexity setups where containers follow predictable routes. RFID, on the other hand, simplifies high-volume automation with bulk scanning capabilities. Ambient IoT solutions, such as those offered by Wiliot, eliminate manual intervention entirely, making them perfect for unpredictable supply chains.

The impact of implementing dedicated tracking systems is striking. Some platforms have reported up to a 60% reduction in lost assets, emphasizing the importance of efficient tracking in optimizing reusable packaging returns and supporting sustainable e-commerce logistics.

Conclusion

Tracking tools transform reusable packaging into a strategic edge. With real-time tracking, companies can reduce lost assets by up to 80% and eliminate 96% of manual tasks. These efficiencies lead to quicker turnaround times - on average, 31% faster - while also preventing the loss of containers valued at $800 million to $1.5 billion annually across the industry.

But the benefits go far beyond operational improvements. Tracking systems play a key role in reducing waste and supporting environmental goals. By maximizing reuse cycles, they align with the EU's PPWR target of 40% reusable transport packaging by 2030. In fact, IoT-enabled reusable packaging can achieve 60% CO2 savings compared to single-use options, making these tools indispensable for regulatory compliance and corporate sustainability efforts.

As Radiant emphasizes:

"Tracking returnable containers is essential to preserving our planet's limited resources." - Radiant

Additionally, these tools enhance supply chain resilience. Integrating tracking software with logistics systems creates a unified data flow, eliminating silos and automating workflows to prevent shortages and costly last-minute freight.

JIT Transportation provides tailored 3PL solutions that complement reusable packaging strategies. From integrated distribution and returns management (RMA) to ERP integration, their services ensure you can recover assets efficiently while scaling operations to meet evolving sustainability goals. Combining tracking tools with a logistics partner that understands the intricacies of returnable transport items can help you achieve both operational and environmental success.

FAQs

Should I use QR codes, RFID, or IoT sensors for tracking returns?

The right option hinges on what you need in terms of visibility, automation, and real-time insights. QR codes are a budget-friendly option for manual tracking. If you’re dealing with high volumes and need speed, RFID is great for automated identification without requiring line-of-sight. Meanwhile, IoT sensors excel in real-time tracking and proactive management, making them a smart pick for intricate supply chains. For setups focused on cost, QR codes or RFID can do the job, but IoT is better suited for advanced operations.

How do I integrate reusable packaging tracking with my ERP/WMS?

Integrating reusable packaging tracking with your ERP or WMS means leveraging asset tracking systems that sync data in real time. Technologies like RFID or barcode systems can help you keep tabs on reusable items like bins or containers with precision. By adding advanced software modules built for managing returnable packaging, you can streamline operations, boost inventory accuracy, and gain better visibility - all while working smoothly with your current systems.

What return rate should I target to make reusables pay off?

To make reusable packaging work financially, you need a return rate of at least 98%. This ensures the majority of containers are recovered and put back into use. Some programs even report return rates above this level. Achieving such high recovery rates is crucial for getting the most value out of reusable systems and keeping them efficient.

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