Containers for safe processes and smart picking

Efficient and trouble-free processes are the foundation of modern retail logistics. Storage and transport containers play a central role in the picking of small parts. Bekuplast has developed a container solution for the Rossmann drugstore chain that significantly improves both process reliability and efficiency.

Landsberg central warehouse as the logistical centerpiece

Rossmann is one of the leading drugstore chains in Europe and operates over 2,300 stores in Germany alone. The central warehouse in Landsberg near Halle is the central hub for the supply of goods. From here, around 19,000 items are assembled for the stores every day and delivered to the regional locations. The central warehouse goods are then supplemented with the picked regional goods and delivered to the Rossmann sales outlets.

The containers previously used had reached their design limits in the container storage areas. The permanently high loads led to deflection of the container bases and caused faults in the conveyor technology. In addition, disposable cardboard and adhesive tape were used to prevent small items from falling out of the removal opening and over the edge of the container. As part of a container replacement in the central warehouse, a new solution was developed to optimize these points.

Clear objectives for the new generation of containers

The new generation of containers had to ensure process reliability in conveyor technology, reliably secure the goods and make order picking ergonomic and efficient. Since September 2025, Rossmann has been using a newly developed special container from Bekuplast in its central warehouse and e-commerce warehouse that optimally meets these requirements.

Robust construction, transparent removal flaps

The new special container has a stable double base that can withstand high loads and ensures trouble-free operation in the conveyor system. For goods removal, the container has two transparent removal flaps that can be operated with one hand. Depending on the fill level, the flaps can engage in three different positions, which makes order picking much easier. The fire protection regulations posed a particular challenge. Instead of a classic lid, a VDS-compliant safety grid is therefore used. This grid is fixed to the container frame and reliably prevents goods from falling out during transportation or order picking. It can be attached and removed just as easily with a single movement.

The height-adjustable sliding flap of the container allows goods to be removed quickly and ergonomically. The sliding flap can be opened and closed with one hand. The container also has barred handles, integrated in-mold labels, openings for automation grippers and dimple fields for adhesive labels. These details ensure safety, efficiency, smooth integration into automated processes and clear labeling.

More process reliability and sustainability

The new container solution from Bekuplast increases process reliability, simplifies order picking and eliminates the need for disposable materials. The result is fewer disruptions, greater efficiency and a significantly improved ecological balance. This project shows how container solutions can contribute to process optimization and the implementation of sustainable material cycles. The containers previously used by Rossmann in the central warehouse and in the e-commerce warehouse were taken back and recycled by Bekuplast. By returning the materials to the production cycle, resources are conserved and the plastics used remain usable in the long term in line with the circular economy.