To make the transport of products in large load carriers such as Mega-Packs or Hyboxes even more efficient, the Walther Faltbox Group is expanding its range to include an innovative intermediate level. This solution enables the horizontal subdivision of foldable large containers without restricting their ability to reduce volume.
The design is based on stable crossbars, which are fixed in the container walls using patented plastic holders. A load-bearing structural chamber panel is placed on top of this to create an additional level.
„With this addition, we are responding specifically to the needs of our customers. The ability to divide large load carriers horizontally with free-floating intermediate layers allows us to use resources more efficiently, optimise logistics processes and offer our customers a smart solution for modern supply chains.“
Florian Herkenrath, Project Manager at the Walther Faltbox Group.
Designer Stephan Engelhardt explains what was particularly important to the company during development: „As with all of our products, we placed great emphasis on sustainability, user-friendly handling and durability. This is how we designed the solution, that it works for different sizes and can therefore be used with a variety of large load carriers. In addition, the containers can still be reduced in volume once the crossbars have been removed.“
The advantages of the new solution are obvious: it Enables better space utilisation and ensures greater load safety, as products do not have to be stacked directly on top of each other. This means that even sensitive goods are better protected. The intermediate level also facilitates order picking and makes transport logistics more efficient - especially for just-in-time supply chains.
Economic and ecological aspects also play a role: the flexible use of the intermediate layer reduces costs and contributes to sustainability, as the reusable containers save resources. The new intermediate level is therefore an ideal addition to the compartments, trays or foam parts with which the large containers are already individually equipped today.
Focus on sustainability and automation
Innovative solutions for sustainable logistics are a central concern of the Walther Faltbox Group. In addition to developing efficient reusable load carriers, the company also focuses on smart technologies such as RFID inmould labels, which are integrated into the containers. These enable seamless traceability and improve the control of reusable systems. As a result, reusable systems can be controlled more efficiently and the service life of the products can be optimised.
Source: Walther folding systems
Walther Faltsysteme at LogiMAT 2025: Hall 6, Stand A05
