Stack and nest containers
Stack and nest containers are hand-held totes with tapered walls: loaded, they stack on one another; empty, they drop inside each other and take a fraction of the space. Distribution centers, food plants and growers use them where full boxes go out and empty boxes come back.
- Nest ratio
- Up to 4:1 (ORBIS, Buckhorn models)
- Styles
- 180-degree turn, bail arm, lid
- Common footprints
- 24x16 metric, 24x20, 29x19
- Wall
- Tapered so empties drop inside
Three ways a tote switches from stack to nest
Turn it 180 degrees. The most common design has stacking ledges molded at different points on each end. Face the totes the same way and the upper one rests on the ledges; spin it half a turn and it slides down into the one below. Buckhorn's SN29191002 and IPL Schoeller's Bicolour line both work this way, and ORBIS describes its Polylewton totes nesting at an alternating 180 degree position.
Swing a bail arm. A steel bar hinged across the top carries the tote above when it is closed over the opening. ORBIS says its AF2416-13 "Stacks securely with bail arm engaged" and nests once the zinc-plated arm is swung open. Bail arms suit fast, repetitive work, since nobody has to check which end faces which way.
Add a lid. ORBIS notes its stack-and-nest containers can also stack full with a cover on. Akro-Mils says its Nest & Stack Totes stack with or without optional lids. A lid turns the tote into a closed shipper, though for a box that keeps its lid on a hinge, see attached-lid containers.
Maker models, sizes and trailer counts
Footprints in this family come in both inch and metric families. ORBIS designed its GS6040 on a metric base and publishes it as 23.6 x 15.8 in, close to the 600x400 mm module; its GS6050 is 23.6 x 19.7 in, which sits on our 24x20 page, in 7.6, 11.2 and 14.8 in heights. Each figure below comes from the maker's own product page.
| Maker | Model | Outside (in) | Capacity / volume | Tare | Nest ratio | Per 53 ft trailer |
|---|---|---|---|---|---|---|
| ORBIS | GS6040-27 | 23.6 x 15.8 x 10.7 | 1.6 cu ft | 4.3 lb | 3.0:1 | 3,900 |
| Buckhorn | SN29191002 | 28.8 x 18.8 x 10.4 | 100 lb | 5.6 lb | 4:1 | 840 stacked, 3,060 nested |
| ORBIS | AF2416-13 (bail arm) | 23.6 x 15.8 x 13.2 | Not listed | 6.5 lb | 3:1 | Not listed; 5 per layer on 40 x 48 |
| Akro-Mils | 35225 | 23-1/2 x 19-1/2 x 10 | 70 lb, 14.98 gal | Not listed | Not listed | Not listed |
| ORBIS | Polylewton | Several sizes | 70 lb per tote; bottom tote carries 300 lb stacked | By size | Not listed | Not listed |
How much room the nest saves
Buckhorn's figures for the SN29191002 make the point plainly: about 840 totes fit a 53 ft truck stacked, and about 3,060 nested. That gap is the whole reason to buy this style when empties travel back to a supplier, a store or a field. IPL Schoeller says its 180-degree containers save "up to 80 percent of space", and claims up to 81 percent for its Maxinest trays.
Treat each figure as belonging to one model. A tall, steep-walled tote nests deeper than a shallow tray, and the ratio a maker prints assumes clean, undamaged boxes. Our return ratio guide explains why ratio and trailer count don't move in lockstep, and the trailer fill tool lets you test a count against your own lane.
The taper has a cost inside the box. Because the floor is smaller than the opening, a nest-stack tote holds less than a straight-wall crate of the same outside size, and partitions won't fit snugly against sloped sides. If you need inserts or every cubic inch, a straight-wall crate is the better fit. Buckhorn rates its stack & nest line for -20 to 120 F, worth checking for blast freezers or summer docks.
Where nest-stack totes work
Picking and store delivery in distribution and 3PL buildings and grocery and retail chains. Field picking and in-plant handling in agriculture, where ORBIS sizes its bail-arm totes to the 40 x 48 pallet. Trimming and case-ready lines in meat and poultry and other food processing rooms, where totes get washed every shift.
On food contact, quote the maker and confirm it on paper. Buckhorn says its stack & nest containers are "Constructed of FDA-compliant materials"; ORBIS says the GS6040-27 is "Available in FDA-approved material", which means you specify it when ordering. We don't certify either. Tell us what goes in, and for used totes, what they held before.
Buying used: what to look at
Used nest-stack totes turn up when a retailer changes its tote program or a plant swaps colors. They are worth a look for internal use, overflow and seasonal work. We grade lots A, B or C (see used container grades) and the general checks are on buying used. For this style, add three of our own.
- Stacking ledges. A chipped ledge lets a loaded tote slip down into the one below. Stack two full ones and push.
- Bail arm pivots. Bent arms or worn pivot holes stop the arm sitting flat across the rim.
- Jammed nests. Warped walls make totes wedge together. Pull ten apart before you accept a lot.
What to send for a quote
Send these on the quote form or to info@plasticcratesforsale.com and we'll come back with matching models.
- Outside footprint and height, or a maker part number
- Rotation, bail arm or lid style
- Load per tote and how high you stack full
- Quantity, new or used, and where empties go
- Food contact needs and the tote's prior contents if used
Questions
What is a nest ratio?
It compares how many empty totes fit, nested, in the height one tote takes standing. ORBIS lists 3.0:1 for its GS6040-27 and Buckhorn 4:1 for the SN29191002.
Rotation or bail arm: which is better?
Neither wins outright. Rotation totes have no moving parts; bail-arm totes stack without anyone checking orientation, which helps on busy picking lines.
Can I mix totes from two makers?
Usually not in one column. Stacking ledges and tapers vary, so a Buckhorn and an ORBIS tote of similar size may not stack or nest together safely.
Sources
Figures on this page come from these pages, last reviewed 2026-11-08. Makers update their sheets; confirm a model's figures on its current sheet before you order.