How do you calculate total cost of ownership for reusable transport cases?

Thijs Canjels

Thijs Canjels is Business Innovation Manager at Faes and specializes in packaging management and supply chain optimization. In his blogs, he shares insights on efficiency improvements, cost savings and the strategic role of packaging in modern supply chains.

Total Cost of Ownership

How do you calculate total cost of ownership for reusable transport cases?

Total Cost of Ownership shows that packaging costs go far beyond the initial purchase, including damage, transport, and operational expenses. Reusable transport cases reduce cost per use and turn packaging into a strategic advantage.

DOA's

What is the difference between DOA minimization and standard transport packaging?

DOA minimization focuses on engineered, product-specific packaging that prevents damage entirely, reducing failures, costs, and downtime. Unlike standard packaging, it transforms packaging from a cost center into a strategic tool for risk management and supply chain reliability.

Total Cost of Ownership

What is the average TCO of reusable versus single-use packaging?

This article explains how a Total Cost of Ownership (TCO) analysis reveals that reusable packaging can be 30–50% more cost-effective than single-use packaging over time. By factoring in lifecycle costs such as handling, logistics, maintenance, and disposal, it shows why upfront price alone is a misleading decision metric.

Total Cost of Ownership

How do you compare TCO of MIL-STD versus commercial cases?

A Total Cost of Ownership (TCO) comparison shows that the true cost of transport cases goes far beyond the purchase price. MIL-STD cases often deliver lower long-term costs due to greater durability, reduced damage risk, and longer lifecycle performance.

Total Cost of Ownership

How does modular design lower TCO in defense supply chains?

Modular design reduces Total Cost of Ownership in defense supply chains by replacing bespoke packaging with standardized, reconfigurable systems. This approach lowers inventory complexity, improves asset utilization, and increases logistical flexibility across missions and platforms. It shifts packaging from a cost center to a strategic enabler of readiness and efficiency.

Total Cost of Ownership

How does reverse logistics optimize TCO of transport cases?

Reverse logistics transforms transport cases from single-use costs into circular assets. By enabling reuse, refurbishment, and higher utilization, companies can significantly reduce Total Cost of Ownership while improving sustainability and supply chain control.

Total Cost of Ownership

What are realistic TCO benchmarks for industrial packaging?

This article explains why Total Cost of Ownership (TCO) in industrial packaging goes far beyond purchase price, covering hidden costs such as damage, handling, storage, and compliance. It provides realistic TCO benchmarks per sector and shows how strategic packaging decisions can significantly reduce long-term logistics costs while improving reliability and sustainability.

Total Cost of Ownership

What TCO benefits do circular packaging solutions offer in 2026?

Circular packaging solutions reduce Total Cost of Ownership by spreading costs over multiple reuse cycles, lowering waste, logistics, and compliance expenses. In 2026, companies that treat packaging as a long-term asset gain both financial efficiency and measurable sustainability impact.

Total Cost of Ownership

How do you factor damage costs into your TCO calculation?

This article explains why damage costs are often underestimated in Total Cost of Ownership (TCO) calculations and how to properly account for them. By identifying direct, indirect, and hidden damage costs, it shows how smarter packaging decisions can significantly reduce long-term operational and financial risk.

DOA's

Which tests predict DOA risk for your products?

This article explains how targeted transport tests such as vibration, shock, temperature, and humidity testing help predict and reduce DOA risk. By identifying the most critical stress factors early, companies can design packaging that prevents damage, lowers costs, and protects high value products throughout the supply chain.

Total Cost of Ownership

How does longer lifespan reduce TCO of defense packaging?

A longer packaging lifespan directly lowers the total cost of ownership in defense logistics by reducing replacements, damage, and operational disruptions. This article explains why durable, reusable packaging delivers measurable cost savings over its full lifecycle. A must-read for decision-makers focused on reliability, compliance, and long-term value.

DOA's

How do you measure DOA rates in your supply chain in 2026?

Dead-on-Arrival (DOA) rates reveal hidden costs and risks in your supply chain. This article explains how to accurately measure DOA in 2026, interpret the data, and identify root causes across packaging, handling, and transport. Learn how structured tracking helps reduce damage, protect margins, and improve customer satisfaction.

DOA's

How does custom packaging reduce DOA for automotive components?

Custom packaging plays a critical role in reducing Dead-On-Arrival (DOA) rates for automotive components by protecting parts against shock, vibration, moisture, and contamination. By tailoring materials and internal designs to each component, manufacturers can prevent damage, avoid production delays, and significantly lower total supply chain costs.

Total Cost of Ownership

Which maintenance costs affect TCO of industrial cases?

Maintenance costs play a decisive role in the Total Cost of Ownership of industrial cases, often exceeding the initial purchase price. This article explains which hidden and indirect maintenance costs impact TCO, and how preventive maintenance strategies can significantly reduce long-term packaging costs while minimizing downtime and risk.

Total Cost of Ownership

Which TCO factors do procurement teams overlook in packaging quotes?

Many procurement teams focus on upfront packaging costs, while overlooking critical Total Cost of Ownership factors. This article explains how hidden costs such as damage risk, handling time, storage inefficiency, and replacement frequency significantly impact long-term spend. A must-read for procurement professionals aiming to make smarter, lifecycle-driven packaging decisions.

DOA's

Which industries face the highest DOA rates in 2026?

High-tech, medical, and electronics industries face the highest DOA rates in 2026 due to fragile, high-value components and complex supply chains. Poor packaging and handling can drive 2–8% failure rates, making DOA a critical cost and reliability issue in B2B logistics.

Total Cost of Ownership

How do you calculate TCO for high-tech equipment packaging?

This article explains how to calculate the Total Cost of Ownership (TCO) for high-tech equipment packaging by looking beyond purchase price alone. It shows how lifecycle costs such as damage prevention, reuse, logistics efficiency, and end-of-life handling determine the true financial impact of packaging decisions.

Total Cost of Ownership

What is the TCO of custom flightcases versus standard solutions?

This article explains why total cost of ownership matters more than purchase price when choosing between custom flightcases and standard solutions. By comparing lifecycle costs such as damage, efficiency, lifespan, and logistics, it shows when custom cases deliver measurable long-term value.

Total Cost of Ownership

What is TCO and why is it crucial for packaging decisions?

Total Cost of Ownership (TCO) reveals the true cost of packaging by looking beyond purchase price to the full lifecycle impact. By factoring in handling, transport, damage prevention, and sustainability, companies make smarter packaging decisions that reduce risk and lower long-term costs.

DOA's

What does a high DOA rate cost your organization annually?

A high DOA rate silently drives up costs far beyond product replacement, impacting logistics, operations, and customer trust. This article explains how hidden inefficiencies compound annually and why structurally engineered packaging is key to reducing risk and total cost.

Total Cost of Ownership

What is the Total Cost of Ownership for reusable industrial packaging?

Total cost of ownership reveals that packaging costs extend far beyond the initial purchase, including logistics, maintenance, and damage risks across the full lifecycle. Optimized reusable packaging systems reduce hidden costs and create long-term efficiency within the supply chain.

Total Cost of Ownership

How can TCO optimization in packaging solutions save costs?

TCO optimization in packaging reveals hidden costs across the entire lifecycle, from transport and handling to damage and waste. By focusing on total value instead of purchase price, companies can significantly reduce costs while improving efficiency and reliability.

DOA's

What is DOA minimization in transportation?

DOA minimization in transport focuses on preventing products from arriving damaged or non functional by optimizing packaging, logistics, and risk management across the entire supply chain. It reduces costs, improves reliability, and ensures critical equipment reaches its destination in perfect condition.

DOA's

What is the difference between standard packaging and DOA preventive packaging solutions?

Discover the difference between standard packaging and DOA preventive solutions and how they impact risk, cost, and product integrity across the supply chain. Learn why engineered packaging reduces failures, lowers total cost of ownership, and ensures reliable delivery.

DOA's

What is DOA reduction in industrial packaging?

DOA reduction in industrial packaging focuses on preventing damage during transport through optimized design, materials, and logistics. It improves supply chain reliability while reducing costs and protecting customer satisfaction.

Total Cost of Ownership

How do you calculate the total cost of ownership of your logistics packaging in 2025?

The Total Cost of Ownership (TCO) of logistics packaging goes far beyond the purchase price alone: hidden costs such as damage, inefficient handling, returns logistics and waste disposal ultimately determine the true costs. Smart, reusable and well-designed packaging significantly reduces these costs and delivers long-term savings.

Total Cost of Ownership

What is total cost of ownership (TCO) in logistics?

Total Cost of Ownership (TCO) allows companies to look beyond the purchase price and reveals all logistical costs over the entire lifespan. It uncovers hidden costs such as damage, maintenance and inefficiency, enabling you to make informed choices. For example, a more expensive packaging solution often turns out to be the cheapest in the long term.

Total Cost of Ownership

What is the difference between initial acquisition costs and TCO in packaging logistics?

Total Cost of Ownership in packaging logistics goes beyond initial purchase price by capturing all lifecycle costs including handling, maintenance, and replacement. This broader perspective enables smarter decisions, reduces hidden costs, and turns packaging into a strategic value driver.

Total Cost of Ownership

What is TCO optimization for industrial packaging?

TCO optimisation is all about reducing all costs associated with industrial packaging, not just the purchase price. By taking into account lifespan, usage, transport, damage and circularity, packaging becomes a strategic cost-saving factor throughout the entire supply chain.

Total Cost of Ownership

What is TCO for packaging solutions?

TCO in packaging looks beyond the initial purchase price and considers all costs across the entire lifecycle, including logistics, handling, maintenance, and end of life. By focusing on durability, reuse, and damage prevention, businesses can reduce total costs and create more efficient and sustainable supply chains.

Total Cost of Ownership

How do you calculate the total costs of industrial packaging in 2025?

By 2025, industrial packaging will no longer be about the lowest price, but about the total cost over the entire lifecycle. This article by Faes explains how to calculate the Total Cost of Ownership (TCO) and why sustainable, reusable solutions are often the most cost-effective choice.

Sustainability

What are circular packaging solutions in the industrial sector?

Circular packaging solutions in industry reduce waste, cut costs and extend the lifespan of materials. Through reuse, repair and recycling, companies integrate sustainability directly into their supply chain and strengthen their competitive position.

Packaging Management

What is packaging management and why is it important?

Packaging management is a strategic approach that optimizes the entire packaging lifecycle, from design and materials to logistics and sustainability. It uses data-driven insights and circular practices to reduce costs, improve efficiency, and strengthen brand consistency across the supply chain.

Packaging Management

How does packaging management increase supply chain effectiveness?

Strategic packaging management transforms packaging from a cost center into a driver of supply chain efficiency. By optimizing design, materials, and lifecycle, businesses reduce costs, minimize damage, and enhance sustainability across the entire logistics chain.

DOA's

The blind spot in DOA problems: why logistics causes are structurally underestimated

Discover why logistics failures are often the hidden culprits behind DOAs and how simple adjustments to packaging and processes can immediately yield significant gains. Read how you can transform logistics from a blind spot into a strategic asset for your supply chain.

DOA's

Design for Distribution: engineering choices that reduce DOA probability

Discover how you can significantly reduce the risk of defective deliveries (DOAs) right from the design phase by incorporating smart packaging, material and installation factors. Learn how Design for Distribution prevents technical choices from causing headaches, costs and quality losses later in the chain.

DOA's

Field Service Engineers as DOA remedy: training, tooling and installation scripts

Field Service Engineers play a crucial role in reducing DOAs. With the right training, tools, and installation scripts, you can prevent errors, save time, and increase the reliability of your service.

DOA's

Not just material: why one DOA costs >100% of part value

A defective part upon arrival costs much more than you might think. Once you factor in service hours, urgent transport and stock costs, the damage can amount to between 135 and 219 per cent of the material value. Understanding the causes is crucial to protecting margins and securing growth.

DOA's

Root causes unraveled: logistics, part quality and service quality (with NFF)

Discover how logistics errors, component quality and service quality together cause the hidden costs of DOAs. This article shows how root cause analysis and smart improvements can make your supply chain more reliable and cost-efficient.

DOA's

Packaging first: how fewer variants nearly halved DOAs

Discover how reducing packaging variants drastically improves the service chain: lower costs, fewer DOAs and higher customer satisfaction. This article shows how smart choices in packaging deliver immediate results.

Laws and regulations Lithium-Ion packaging

EU Battery Regulation 2027: What does it mean for transport and packaging of lithium batteries?

The EU Battery Regulation imposes strict requirements on the transport and packaging of lithium batteries from 2027 onwards. This article provides insight into new rules concerning QR codes, Battery Passports, return flows and recycling targets.

DOA's

From complaint to opportunity: how DOA can help you improve your supply chain

DOAs may seem like complaints, but they are primarily signals that help improve your supply chain. By analysing causes and optimising processes, you reduce costs, increase reliability and strengthen customer relationships. Faes shows how smart DOA management leads to competitive advantage and sustainability.

Laws and regulations

What is ADR and why is it important for industrial packaging?

ADR regulates the safe transport of dangerous goods and sets strict requirements for industrial packaging. From UN markings to labelling and compatibility, compliance prevents fines and guarantees safety and continuity in the supply chain. Faes helps companies make their packaging fully ADR compliant.

DOA's

The €1,200 reflex: how rush shipments are driving up the real DOA bill

Urgent shipments seem like a quick solution for DOAs, but they can drive costs up to eight times higher than regular transport. This article shows how prevention, detection, and smart inventory strategies not only reduce costs but also structurally increase reliability and customer satisfaction.

Laws and regulations

PPWR: What does the new EU regulation mean for industrial packaging?

The new EU PPWR regulation will impose strict requirements on industrial packaging from 2026 onwards. Companies must focus on reuse, recyclability and digital traceability in order to remain compliant. This article explains what is changing and how your organisation can prepare.

DOA's

Responsibility in DOA: who pays the bill?

Dead on Arrival products incur high costs due to transport, stock and repair work. This article explains who is responsible for these costs and how better packaging and chain collaboration can structurally reduce the number of DOAs.

DOA's

The hidden 4%: how DOAs erode your service revenue and margin

Dead-on-arrival parts may seem like a minor issue, but their impact is significant. On average, companies lose more than 4% of their spare parts revenue due to defective deliveries. Discover the hidden costs and how you can limit them in this article.

DOA's

Service levels at risk: what DOAs do to fill and ready rates

DOAs have a direct impact on service levels and increase costs due to additional demand, urgent deliveries and higher stock levels. This article shows how fill and ready rates come under pressure and offers strategies to limit damage and gain a competitive advantage.

Packaging Management

Whitepaper: Packaging-as-a-Service

Packaging as a Service transforms packaging from a cost item into a strategic tool for cost control, circularity, and compliance. The white paper demonstrates how this model assists companies in operating more sustainably and efficiently within the requirements of the EU Packaging Regulation.

DOA's

Increase inventory against DOA? Only makes sense at extreme ratios

Increasing stock seems like a quick fix for DOA, but often incurs high costs without addressing the real cause. This can only be useful in cases of exceptionally high defect rates, whereas structural improvements in packaging and logistics are almost always more effective.

DOA's

The hidden costs of Dead-on-Arrival (DOA): Why the problem is bigger than you think

Dead-on-arrival products cause more damage than just return costs and replacements. They disrupt production processes, strain customer relationships and increase the ecological footprint. Through better packaging strategies and chain-wide collaboration, Faes helps companies to prevent these hidden costs on a structural basis.

Custom Design & Production

Whitepaper: Customisation for demanding environments

This white paper demonstrates how customised packaging provides protection in the most demanding environments. With a focus on strict standards, sustainability, and first-time-right solutions, you will discover how packaging contributes to safety and efficiency.

Sustainability

Are custom packages reusable?

In this article, you can read how customised packaging can be reused for many transport cycles thanks to strong materials and smart design. You will discover how reuse not only reduces costs but also contributes to sustainability and a circular supply chain.

Packaging Management

Faes – partner in Printed Electronics

Faes strengthens the growth of Printed Electronics through smart collaboration and automated packaging management. With solutions such as RFID tracking, pool management and PackAssist®, we ensure that companies can organise their supply chain more efficiently and focus on their core activities.

DOA's

DOAs snatch 30 percent off profits

In this article, you will learn how Dead On Arrival's (DOAs) consume an average of 30 per cent of profits and why the actual costs are often underestimated. You will also discover how better packaging management and process improvement can drastically reduce damage and increase customer satisfaction.

Sustainability

Socially responsible purchasing and sustainable packaging, are you doing it already?

Socially responsible purchasing and sustainable packaging go hand in hand: less material use, lower costs and a smaller ecological footprint. By packaging smarter and using data, you can optimise efficiency and comply with increasingly stringent sustainability regulations. Faes shows how companies can achieve immediate results with the right approach.

Packaging Management

Prevent packaging problems in your supply chain

Packaging problems in your supply chain lead to higher costs, delays and errors. By standardising packaging and using smart tools such as PackAssist, you can improve efficiency and customer satisfaction. Faes shows how this directly contributes to cost savings and a professional image.

Custom Design & Production

What does packaging have to do with SLAs?

Good packaging is crucial to meeting SLAs, as it directly affects delivery time, quality and customer satisfaction. Poorly packaged products lead to damage and DOAs, resulting in fines and reputational damage. By organising packaging smartly, you reduce risks and increase reliability towards customers.

Sustainability

Why it’s smart to engage in sustainable packaging

Sustainable packaging reduces costs, extends the lifespan of packaging and prepares companies for stricter legislation. It also strengthens your image and contributes directly to a future-proof supply chain.

Packaging Management

5 opportunities for better packaging management

Better packaging management reduces costs, prevents damage and makes processes more efficient. Clear agreements, smarter use of resources and optimal coordination throughout the chain enable you to create immediate value for your business.

Packaging Management

Lean and packaging: 5 eye openers

Lean working does not stop at the production line; packaging also plays a crucial role. By integrating packaging management into Lean processes, you prevent waste, reduce costs and ensure a smoother flow throughout the entire chain.

Packaging Management

A lot of money can be saved with Fourth Party Packaging, but how?

Many companies underestimate the hidden costs of packaging and its impact on customer satisfaction and the environment. With Fourth Party Packaging, you can gain control over processes, reduce costs and lower your carbon footprint. This turns packaging management into a strategic opportunity rather than a blind spot.

Top 4 problems in packaging industrial service parts

Packaging Management

Increase your profitability with Packaging-as-a-Service

With Packaging-as-a-Service, you no longer invest in packaging but only pay for use. This reduces costs, lowers CO₂ emissions and ensures a flexible and scalable packaging process that delivers optimal returns.

Packaging Management

Whitepaper: improve the efficiency of your supply chain

Many companies lose margin unnoticed due to inefficient packaging processes and a lack of control in the supply chain. This white paper shows how you can regain control, reduce costs and improve your return on investment in a sustainable manner with an integrated approach.

Packaging Management

More efficient supply chain: the benefits of good packaging management

Good packaging management prevents errors, reduces transport costs and limits damage. By using clear guidelines and smart software, you can increase efficiency and reliability throughout the supply chain.

Packaging Management

Fourth Party Packaging (4PP) as an extension of Fourth Party Logistics (4PL)

This article explains how Fourth Party Packaging (4PP) is an extension of Fourth Party Logistics (4PL). By strategically managing packaging, a 4PP provider prevents waste and optimises costs, materials and processes in line with the supply chain.

Sustainability

Returnable packaging as a sustainable solution

Returnable packaging reduces waste and minimises the risk of costly DOAs, whilst ensuring more efficient logistics and higher customer satisfaction. By opting for reusable solutions that include cleaning and repair, you extend the product’s lifespan and achieve long-term cost savings.

DOA's

Research: 25% more profit by addressing DOAs

DOAs cause high costs due to returns, repairs and damage to reputation. By tackling them in a targeted manner, companies can achieve up to 25 per cent more profit and strengthen customer relationships. Investing in better packaging solutions pays for itself immediately in terms of cost savings and continuity.

DOA's

What is a DOA?

Dead On Arrival (DOA) means that a product arrives damaged at the customer's premises, immediately incurring high direct and hidden costs. It reduces customer satisfaction, damages your reputation and can amount to as much as 5% of turnover. Good packaging solutions minimise this risk and protect both your margin and your customer relationship.

Packaging Management

Smart Packaging: working together on the smart logistics of the future

Smart Packaging connects packaging with data and enables real-time insight into the supply chain. Sensors and smart algorithms make processes such as order picking and inventory management more efficient, while product quality is better monitored. Collaboration between partners such as Faes and Bright Cape accelerates the path to the logistics of the future.