Nestable or stackable?

How a straight-wall crate stacks

A straight-wall crate has vertical walls and a rim the next crate's feet lock into. ORBIS points out that its straight-wall totes keep consistent dimensions from top to bottom, unlike stack-and-nest styles that taper inward, so dunnage inserts sit flush against the walls. Buckhorn calls its version stack-only modular containers for closed-loop shipping, in-process handling and storage, with an optional cross-stack bottom so a crate can sit across two below it.

The cost is that an empty one takes the same room as a full one. A trailer of empty straight-wall crates is mostly air.

Three ways a nesting tote stacks

• Turn it 180 degrees. The walls carry ledges that only line up one way. Facing the same way the totes nest; turn every other one and they sit on the ledges. ORBIS, Buckhorn and IPL Schoeller all sell this style.
• Swing the bail arms. Steel arms across the top hold the tote above. ORBIS says its AF2416-13 "Stacks securely with bail arm engaged" and nests with the zinc-plated arm open.
• Close the lid. Attached-lid containers stack when closed and nest with lids open; see attached-lid containers. Some plain nest-stack totes also stack on a loose cover.

Maker figures side by side

Ratios here are each maker's own. How ratios are worked out and checked is on the return ratio guide.

What the taper costs you

A nesting tote is narrower at the bottom than at the top, so square items leave gaps at the base and a fitted divider set has to taper too. Machines care: conveyors, robot pickers and automated storage prefer walls that sit at a known position all the way down. Straight walls also give flat, square label areas.

Compare inside space on two 24 x 15 straight-wall models: ORBIS lists 21.5 x 13.1 inches inside the bottom of its NSOA2415-14, and Buckhorn lists the same 21.5 x 13.1 inches with 6.9 inches of usable height and 1.1 cubic feet for its 7.5-inch SW241507F1. A tapered tote of the same outside size loses width toward the floor, which matters most for rigid parts and least for loose produce or bagged goods.

Loads, and a little arithmetic

Nesting styles are generally light-duty hand totes. ORBIS rates its Polylewton stack-and-nest tote at 70 lbs per tote and says the bottom container supports 300 lbs stacked. If every tote above is full at 70 lbs, 300 / 70 = 4.3, so about four full totes can sit on the bottom one. Buckhorn rates its SN29191002 at 100 lbs, and Akro-Mils lists 45 to 100 lbs across nine nest & stack models.

Straight-wall ranges run a bit wider: Akro-Mils lists 30 to 150 lbs across its straight-wall category, with solid, all-mesh or mesh-side versions. Attached-lid totes can be stout when closed; ORBIS lists 800 lbs of static load capacity for its FP182 FliPak. Static and moving limits are explained on our stacking limits guide.

Where each style tends to work

Trades sort themselves fairly cleanly. Buckhorn lists automotive and industrial manufacturing as the industries for its 7.5-inch straight-wall crate, and ORBIS sizes its straight-wall line to the 45 x 48 AIAG pallet so totes tile neatly on a car-plant base. Those loops are short, repetitive and often automated, which suits rigid boxes that never change shape.

Nesting shows up where empties pile up at the far end. Buckhorn names distribution, grocery, retail, wholesale pharmaceutical and general manufacturing for its attached-lid totes, and ORBIS says its FP182 FliPak carries health and beauty items and pharmaceuticals, with molded holes for security ties. ORBIS's 24 x 20 AF-21 bail-arm tote is aimed at produce and case-ready meat. Stores and packhouses rarely have room for empty crates, so a tote that shrinks to a third of its stacked height earns its keep the moment it is unloaded.

If you are still undecided, describe the product, the trip and where empties wait; we'll suggest a style and footprint, and quote new or used.

How to choose, and the folding option

Folding crates give straight walls when standing and a flat pack when empty. ORBIS lists its HHFC2415-11 at 11 inches tall and 3.0 inches folded, and says it interstacks with the maker's rigid NSO2415 StakPak, so a fleet can mix rigid and folding units on one footprint. The trade-off is hinges and latches that can wear; see collapsible crates.

• Long return lane, or a back room with little space for empties: nest-stack or attached-lid.
• Automation, conveyors or robots: straight wall or folding.
• Custom dunnage that must sit flush: straight wall.
• Security ties or tamper evidence: attached-lid.
• Heavy, dense parts: straight wall with a maker rating to match.
• Mixed fleet already in use: stay on its footprint and stacking style.