RFID-Based Control of Returnable Pallets and Reusable Packaging

Returnable pallets travelled with configured sets of reusable packing components, including C-corners and flat sheets. The operating unit was a complete reusable packing set rather than only the pallet underneath it.

The manufacturer needed item-level visibility over approximately 3,000 pallets and their reusable components, including dispatch, customer association, returns and availability. The workflow had to verify a forklift carrying two pallet loads without requiring individual manual scans.

The project combined software customization, RFID tagging, hardware integration, gate deployment and operational testing around the real two-pallet forklift movement pattern. The system was delivered in 2020; current operational status has not been confirmed.

TechnoBeez assigned RFID identities to each pallet and reusable packing component and registered the relationships in customized software.

A customized RFID gate captured the tagged assets as a forklift carried two pallets through the read zone. The interface showed scan progression against the expected 22 components for each pallet.

A complete configured set received a green confirmation, while a short count remained visible for operational review before dispatch continued.

• Pallet- and component-level identity and movement records for dispatch, customer assignment, return and availability.
• Configured 22-component verification with visible scan progression and completion confirmation.
• An auditable basis for dispatch control, customer follow-up and returnable-packaging inventory review.