Reprocessing Service
Box Repair & Refurbishment
Not every used box needs to be recycled or discarded. Our reprocessing facility repairs, resizes, reconditions, and prints on corrugated containers — extending their useful life by multiple cycles and saving your business 55-70% compared to buying new.
Reprocessing Services
What We Can Do with Your Boxes
Box Repair
Structural repairs to damaged corrugated containers — torn flaps reattached, crushed corners reinforced, blown-out bottoms patched or replaced, and delaminated walls re-glued. Our repair process uses corrugated-compatible adhesives and reinforcement techniques that restore load-bearing capacity to manufacturer specifications.
Custom Resizing
Existing boxes resized to your exact dimensional requirements. We score, cut, and reform boxes to new length, width, and height specifications — turning oversize boxes into right-sized containers that reduce dimensional weight charges, void fill, and material waste. Minimum order: 50 units.
Printing & Labeling
Single and multi-color flexographic printing applied directly to reprocessed boxes. Add your logo, handling instructions, UPC barcodes, or compliance markings. We also apply pre-printed labels and stickers for lower-volume customization needs.
Reconditioning
Full reconditioning process that takes a Grade B or C used box to near-new condition. Includes tape and label removal, surface cleaning, flap re-scoring for crisp folds, and visual inspection. Reconditioned boxes are virtually indistinguishable from new in function and appearance.
Flap Modifications
Full-overlap, half-slotted, and telescope conversions applied to standard RSC boxes. Custom flap styles created for specific product protection requirements. Score-line adjustments for products that need non-standard closure configurations.
Reinforcement & Upgrades
Edge protectors, corner guards, corrugated pads, and partition inserts added to reprocessed boxes. We can upgrade single-wall containers with internal reinforcement panels that approach double-wall performance at significantly lower cost.
Full Capabilities
20 Types of Modifications Available
From basic cleaning to complex structural rebuilds, here is every modification we offer — organized by category with turnaround times for standard processing.
| Modification | Category | Description | Turnaround |
|---|---|---|---|
| Flap Repair / Reattachment | Structural | Torn or detached flaps re-glued with industrial corrugated adhesive. Score lines restored for clean folding. | 3-5 days |
| Corner Reinforcement | Structural | Crushed or weakened corners reinforced with corrugated angle boards or internal bracing. | 3-5 days |
| Bottom Replacement | Structural | Blown-out or weakened bottom panels replaced with new corrugated of matching flute and weight. | 5-7 days |
| Wall Panel Replacement | Structural | Damaged wall panels cut out and replaced with matching corrugated. Seams reinforced for structural integrity. | 5-7 days |
| Custom Resizing (L/W/H) | Dimensional | Box scored and cut to new dimensions on all three axes. Tolerances to +/- 1/8 inch. | 5-7 days |
| Height Reduction | Dimensional | Boxes trimmed to reduced height for products that do not require full depth. The most common resizing request. | 3-5 days |
| Score Line Adjustment | Dimensional | New score lines added or existing scores repositioned for different folding configurations. | 3-5 days |
| Flap Conversion (RSC to FOL) | Dimensional | Regular slotted container converted to full-overlap or half-slotted configuration for enhanced protection. | 5-7 days |
| Telescope Conversion | Dimensional | RSC box converted to two-piece telescope design for items requiring top-loading access. | 5-7 days |
| Flexographic Printing | Cosmetic | Single or multi-color print applied to box surfaces. Logos, handling icons, barcodes, text. | 7-10 days |
| Label Application | Cosmetic | Pre-printed labels applied to specified locations. Suitable for branding, compliance, or identification. | 3-5 days |
| Tape & Label Removal | Cosmetic | Previous tape, labels, and adhesive residue removed for clean appearance. | 3-5 days |
| Surface Cleaning | Cosmetic | Dry cleaning of dust, surface dirt, and light stains. No water used to prevent fiber damage. | 3-5 days |
| Brand Cover-Up | Cosmetic | Previous branding or printing covered with kraft liner or overprint for neutral appearance. | 5-7 days |
| Internal Partition Insert | Enhancement | Custom-cut corrugated dividers added for product separation within the box. | 5-7 days |
| Edge Protector Addition | Enhancement | Corrugated or solid fiber edge protectors bonded to corners for stacking strength. | 3-5 days |
| Internal Reinforcement Panel | Enhancement | Corrugated liner panel bonded to interior walls to increase burst and crush resistance. | 5-7 days |
| Pad / Cushion Insert | Enhancement | Die-cut corrugated pads or cushions fitted to box interior for product protection. | 5-7 days |
| Hand-Hole Addition | Enhancement | Die-cut hand holes added to box walls for ergonomic carrying. Reinforced to prevent tear-out. | 5-7 days |
| Vent Hole / Perforations | Enhancement | Ventilation holes or perforated tear strips added for airflow or easy-open functionality. | 3-5 days |
What Can Be Reprocessed
Most corrugated material with at least 70% structural integrity remaining is a candidate for reprocessing. Common inputs include:
- Single-wall corrugated boxes (32 ECT, 200# test and above)
- Double-wall and triple-wall containers
- Gaylord boxes and bulk containers
- Die-cut and specialty boxes (case-by-case evaluation)
- Corrugated pads, sheets, and dividers
- Pallet boxes and octabins
Not sure if your material qualifies? Send us photos or bring a sample to our facility — we assess at no charge.
What Cannot Be Reprocessed
Some materials are beyond repair and go directly to our recycling stream. We cannot reprocess:
- Boxes with mold or active moisture damage
- Corrugated contaminated with hazardous materials
- Material with more than 30% structural fiber failure
- Wax-coated corrugated (not compatible with adhesive repair)
- Boxes with extensive rodent or pest damage
Material that fails reprocessing assessment is not wasted — it goes directly to our recycling program for responsible processing.
Material Sourcing
Three Ways to Source Input Material
Customer-Supplied Material
You provide the boxes, we reprocess them. This is the most cost-effective option when you have surplus or damaged corrugated that can be repaired or resized for your own use. You ship or deliver material to our facility, and we return it reprocessed.
Seattle Boxes Sourced Material
We source used boxes from our inventory or supplier network and reprocess them to your specifications. Ideal when you need a specific size or configuration but do not have input material. Combines our box selling and reprocessing services.
Hybrid Approach
You supply some material, we supplement from our inventory to meet your total order quantity. Common for businesses that generate some surplus but not enough for their full reprocessing needs.
The Process
Six-Stage Reconditioning Process
Every reprocessed box passes through a rigorous six-stage workflow that ensures consistent quality, dimensional accuracy, and structural performance.
Intake & Assessment
Every box is inspected individually. We assess structural integrity, contamination level, and cosmetic condition. Boxes are sorted into repair, resize, recondition, or recycling streams.
Cleaning & Prep
Tape, labels, staples, and surface contaminants are removed. Boxes are cleaned with dry methods to avoid moisture introduction. Printing is evaluated — customer-specific branding is covered or removed per your requirements.
Repair & Modification
Structural repairs are executed. Resizing is performed on a precision scoring and cutting table. Flap modifications, reinforcements, and upgrades are applied. Every modification follows corrugated engineering best practices.
Printing & Finishing
If printing or labeling is requested, it is applied after all physical modifications are complete. Boxes are folded flat, bundled, palletized, and shrink-wrapped for delivery.
Quality Control
Random sampling from every batch is tested for burst strength, edge crush test (ECT) compliance, and dimensional accuracy. Boxes that fail QC are pulled and recycled — they never ship to customers.
Delivery
Finished boxes are delivered to your facility via our fleet, or held for customer pickup. Typical turnaround is 5-7 business days from material receipt. Rush processing available for 2-3 day turnaround.
Quality Assurance
Six Quality Checkpoints
Our QC process is designed to ensure that every reprocessed box meets the same performance standards as new corrugated. Here are the six checkpoints every box passes through.
| Checkpoint | Stage | Tests Performed | Pass Rate |
|---|---|---|---|
| Incoming Inspection | Before processing | Visual assessment, moisture meter reading, manual compression test, fiber quality evaluation | 70% of incoming material passes for reprocessing |
| Post-Repair Structural Test | After repair/modification | Repaired areas tested for bond strength, compression resistance, and flex durability | 95% pass rate on repairs |
| Dimensional Verification | After resizing | Three-dimensional measurement against order specs. Tolerance: +/- 1/8 inch standard, +/- 1/4 inch economy | 98% within tolerance on first cut |
| Burst Strength Test (Mullen) | Random batch sampling | Hydraulic burst test per TAPPI T-810. Must meet minimum PSI for stated wall type. | 97% of reprocessed boxes meet or exceed minimums |
| Edge Crush Test (ECT) | Random batch sampling | TAPPI T-811 edge crush test. 32 ECT minimum for single-wall, 48 ECT for double-wall. | 96% pass rate on reprocessed material |
| Final Visual Inspection | Before palletizing | Cosmetic assessment, print quality verification, label placement accuracy, overall presentation | 99% pass rate on final visual |
Replacement Guarantee
If any reprocessed box fails to perform as specified, we replace it at no charge. No questions, no fine print. QC test reports are available upon request for any order. We retain quality records for 12 months.
Cost Savings
Reprocessed vs. New Manufacturing
The economics are straightforward. Reprocessed boxes deliver functionally identical performance at a fraction of the cost of ordering new from a corrugated manufacturer.
| Box Type | New Cost | Reprocessed Cost | Savings |
|---|---|---|---|
| Standard RSC (18x14x12) | $2.10 - $2.80 | $0.65 - $1.20 | 55-70% |
| Large RSC (24x18x18) | $3.40 - $4.50 | $1.10 - $1.90 | 55-65% |
| Double-Wall Heavy Duty | $5.80 - $8.00 | $2.00 - $3.50 | 55-65% |
| Gaylord Box | $18.00 - $30.00 | $6.00 - $12.00 | 60-70% |
| Custom Resized Box | $3.00 - $6.00 (custom die) | $1.00 - $2.50 | 55-65% |
Where the Savings Come From
Cost Element Breakdown
| Cost Element | New Box | Reprocessed | Impact |
|---|---|---|---|
| Raw Material | 35-45% of total cost | Near zero — uses existing corrugated | Eliminates virgin fiber cost entirely |
| Custom Die / Tooling | $300 - $800 per SKU | $0 — no die required | Full elimination of tooling cost |
| Manufacturing | 25-35% of total cost | Labor + adhesive only | 60-80% lower processing cost |
| Minimum Order | Typically 500-1,000 units | 50 units | Access to custom sizes at low MOQ |
| Lead Time | 2-4 weeks for custom | 5-7 business days standard | 50-75% faster delivery |
| Environmental Cost | Full virgin fiber lifecycle | Extends existing material lifecycle | 75%+ lower carbon footprint |
Turnaround Times
Processing Times by Service Type
Turnaround times begin when material is received at our facility. Rush processing is available for all service types at the surcharges shown.
| Service Type | Standard | Rush | Rush Surcharge |
|---|---|---|---|
| Basic Reconditioning (clean, re-score, inspect) | 3-5 business days | 1-2 business days | +25% |
| Structural Repair (flap, corner, bottom) | 5-7 business days | 2-3 business days | +30% |
| Custom Resizing | 5-7 business days | 2-3 business days | +30% |
| Printing (1-2 colors) | 7-10 business days | 3-5 business days | +35% |
| Printing (3+ colors or full coverage) | 10-14 business days | 5-7 business days | +40% |
| Enhancement (partitions, pads, reinforcement) | 5-7 business days | 3-5 business days | +30% |
| Full Reprocessing (repair + resize + print) | 10-14 business days | 5-7 business days | +35% |
Limitations
Limitations & Restrictions
We believe in full transparency. Here are the known limitations of reprocessing used corrugated. Understanding these helps set accurate expectations for your project.
Maximum size reduction
A box can be resized down by up to 40% on any single dimension before structural integrity is compromised by excessive scoring. Reductions over 40% require panel replacement.
Size increase not possible
Boxes cannot be made larger than their original dimensions. If you need a larger box, we source one from inventory and resize down to your spec.
Print coverage limitations
Flexographic printing on used corrugated may show slight variation due to surface texture differences. For photo-quality or full-bleed printing, new corrugated is recommended.
Minimum order for resizing
50 units minimum for custom resizing jobs. This covers setup time for scoring table adjustment. Smaller quantities are accepted at a setup surcharge.
Fiber degradation over cycles
Corrugated fibers shorten with each use and processing cycle. We test fiber quality on intake and will advise if material has degraded to the point where reprocessing is not advisable.
Color matching
Flexographic ink colors on used corrugated may appear slightly different than on new material due to background color variation. We provide press proofs for approval before production runs.
Wax-coated material
Wax coatings prevent adhesive bonding. Waxed corrugated cannot be repaired, resized, or printed using our standard processes.
Hazardous material contamination
Corrugated that has contained or been contaminated by hazardous materials cannot be reprocessed due to worker safety and downstream contamination concerns.
Environmental Impact
Quantified Environmental Benefits
Reprocessing is the highest-value environmental outcome for corrugated material — even better than recycling. Here is exactly how much impact each reprocessed box makes.
75% lower
Carbon Footprint
Reprocessing uses a fraction of the energy of new manufacturing, resulting in 75% lower CO2 emissions per box.
Near zero
Water Usage
Our dry processing methods use essentially no water, compared to 7-10 gallons per pound in virgin corrugated manufacturing.
100%
Tree Conservation
Every reprocessed box is one fewer box manufactured from virgin fiber. Zero trees harvested for reprocessed output.
100%
Landfill Diversion
Material that would otherwise be recycled or discarded gets additional use cycles, further reducing waste volume.
80%+
Energy Savings
Reprocessing consumes approximately 80% less energy than manufacturing new corrugated from virgin or even recycled fiber.
95%+
Chemical Reduction
No pulping chemicals, no bleaching agents, no sizing chemicals. Only corrugated-compatible adhesives used in repair processes.
Custom Requests
Custom Modification Request Process
Have a unique reprocessing requirement? Here is exactly how we handle custom modification requests from initial inquiry through delivery.
Submit Your Requirements
Tell us what you need: dimensions, wall type, quantity, modifications, printing, and timeline. Include photos of existing material if you are supplying input boxes.
Feasibility Assessment
Our reprocessing engineer evaluates whether your requirements can be met with used corrugated, identifies the best input material, and confirms technical feasibility.
Quote & Approval
We provide a detailed quote covering per-unit cost, setup fees (if any), turnaround time, and input material sourcing cost (if we supply). You review and approve.
Sample Production
For first-time orders or complex modifications, we produce 3-5 samples for your approval before proceeding with the full production run. Samples ship within 3-5 business days.
Full Production
Upon sample approval, we begin full production. Quality control checkpoints are applied at every stage. Production time depends on order complexity and volume.
Delivery & Feedback
Finished boxes are delivered to your facility. We follow up within 48 hours to confirm satisfaction and address any adjustments needed for future orders.
Reprocessing FAQ
Common Questions About Reprocessing
Can I send you my own boxes for reprocessing?
Absolutely. Customer-supplied material is our most common input source. You ship or deliver your surplus, damaged, or wrong-size boxes to our facility, and we return them reprocessed to your specifications. This is the most cost-effective approach because you avoid paying for input material. We charge only for the reprocessing services performed.
How much does reprocessing cost compared to buying new?
Reprocessed boxes typically cost 55-70% less than equivalent new corrugated from a manufacturer. The savings are even more dramatic when you factor in the elimination of custom die costs ($300-$800 per SKU for new boxes) and our lower minimum order quantities (50 units vs. 500-1,000 for new). For a business spending $10,000/month on new corrugated, switching to reprocessed can save $5,500-$7,000/month.
Is the quality of reprocessed boxes reliable?
Yes. Every reprocessed box passes through our six-stage quality control process including burst strength testing, edge crush testing, and dimensional verification. Our replacement guarantee means that if any box fails to perform as specified, we replace it at no charge. Many of our clients use reprocessed boxes for customer-facing shipments without issue.
What is the minimum order for reprocessing?
Custom resizing requires a minimum of 50 units to justify setup time. Basic reconditioning (cleaning, re-scoring, label removal) has no minimum for customer-supplied material — even a single pallet is accepted. Printing minimums depend on the number of colors and coverage area; typically 100+ units for single-color and 250+ for multi-color.
Can you match a specific box I currently buy from a manufacturer?
In most cases, yes. Provide us with the dimensions, wall type, ECT rating, and any printing specifications, and we will replicate it using reprocessed material. The only limitations are situations where the exact flute profile or specialty coating is critical to performance — we will be transparent if reprocessed material cannot match a specific requirement.
How do I know if my boxes are worth reprocessing vs. recycling?
As a general rule, if the box retains at least 70% of its structural integrity and is free of mold and hazardous contamination, it is a candidate for reprocessing. Reprocessing is almost always more valuable than recycling — even a basic reconditioning job recovers 5-10x the value of recycling the same material. When in doubt, send us photos or bring samples and we will assess at no charge.
Give Your Boxes a Second Life
Send us your surplus, damaged, or wrong-size boxes and we will return them reprocessed, resized, and ready for use — at a fraction of new-box cost.