Case Study: National Dairy Producer

From Cardboard Totes to Reusables: Reducing Waste & Risk in the Dairy Supply Chain

The Challenge - 
Cardboard totes were slowing down operations. They required time-consuming setup, didn’t hold up under heavy product weight, and created messy disposal issues for the end customer. The dairy processor faced frequent product damage and rising labor costs.

The Solution - 
They dairy processor implemented the CHEP reusable container rental program to replace cardboard with durable, hygienic IBCs. The switch eliminated the need to assemble, bail, and dispose of cardboard—cutting labor hours by up to 15 minutes per container. With reusable totes, the processor improved product safety, reduced residual loss, and streamlined their bulk handling process.

Dairy Accountability Manager

"We wanted to get out of cardboard totes. Container assembly was difficult and slow, and it was tough to keep facilities clean with the mess they made."

cardboard IBC disposal
Typical cardboard bins require bailing and disposal

About the Customer
A major U.S. dairy processor supplies buttermilk, creamers, fruit drinks, and sour cream to restaurants, retailers, schools, hospitals, and vending companies nationwide. Many of these products rely on Intermediate Bulk Containers (IBCs) during manufacturing and transport.


While using cardboard totes to move liquid ingredients, the processor faced:

Time-consuming setup and teardown for each tote

Excessive waste from bailing and disposing cardboard

Food safety and product quality risks

The Results

reusable CHEP IBCs
Reusable IBCs stack and store efficiently until picked up for next use

The dairy processor wanted to eliminate cardboard but couldn’t justify the capital investment to buy and manage their own reusable containers. Instead, they partnered with CHEP for a full-service rental program—gaining all the benefits of reusables without the hassle. Just ship it and forget it.

Switching to reusable containers delivered major improvements:

15x Less Labor
Setup and teardown time dropped dramatically—freeing up staff and reducing operational strain.

49% Less Waste
Eliminating cardboard cut disposal costs and improved the company’s environmental footprint.

Stronger Protection
Durable IBCs reduced product damage during transport and improved handling reliability.

Cleaner, Safer Facilities
No more cardboard scraps or strapping debris—just clean, organized workspaces.

Smarter Inventory Management
Better tracking and visibility supported food safety compliance and streamlined supply chain operations.

By partnering with CHEP, the dairy company simplified bulk handling—ditching cardboard for a smarter, cleaner solution.

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Case Study: National Dairy Producer | CHEP USA