Reusable Shipping Boxes for Orthopaedic Technology & Medical Supply Stores

Orthopaedic technology

Plaster cast or 3D scan out to production, prosthesis, orthosis or insole back: in orthopaedic technology, custom work travels between medical supply store, workshop and central production every day.

With reusable shipping boxes from hey circle this turns into a closed loop: 94 % less packaging waste than a single-use cardboard box (Box L over 50 cycles, Ökopol life cycle assessment 2023) and better protection for sensitive made-to-measure items.

Box L compared with a single-use cardboard box of the same size containing 80 % recycled material, calculated over 50 cycles. Data source: Ökopol life cycle assessment. The 53 % are an average from real customer calculations.

Three usage patterns

  • Made-to-measure items in a two-way loop

    Measurements out, made-to-measure item back - the packaging travels full in both directions, no empty return shipment.

  • Store replenishment for chains

    Goods from the central warehouse to the stores, the return trip filled or folded flat and bundled - more on store replenishment.

  • Loans to patients

    Orthoses and assistive devices go out in the reusable packaging and come back protected in it.

How the loop works

The medical supply store or the orthopaedic workshop takes the measurements from the patient - as a plaster cast or a 3D scan model - and sends them to central production in the hey circle box. The finished prosthesis, orthosis or insole comes back in the same box - for an average of 50 cycles.

  • Pack & close

    • Place the cast or 3D scan model in the box, safely padded
    • Close the box all round with the zip or slip-on lid for tamper-evident protection - no tape needed
    • Optionally secure the shipment with a security seal

  • Ship

    • Stick the shipping label onto the label holder
    • Hand the parcel over to your carrier as usual
    • hey circle is carried without issue by all major parcel carriers

  • Return

    • The finished prosthesis, orthosis or insole comes back in the same box
    • Peel off the old label without residue, stick on the new one
    • Store empty boxes folded flat to save space, or refill them right away

Mehr aus dem Gesundheitshandwerk

Orthopaedic technology & reusables: a dream team

  • High frequency

    Around 4,500 businesses in Germany work in constant exchange with central production facilities - that is exactly what a reusable loop is built for.

  • Save three times over

    According to the Ökopol life cycle assessment (2023), the hey circle Box L saves 94 % packaging waste and 76 % CO2 over 50 cycles compared with a single-use cardboard box of the same size containing 80 % recycled material. Packaging costs fall by 53 % on average, based on real customer calculations. The box travels full in both directions, so there is no empty return shipment.

  • Protection

    Plaster casts, models and finished orthoses are one-off items. Dimensionally stable boxes with padding protect better than yet another cardboard box - tested in a drop test from 80 cm.

  • Hygiene

    The surfaces are made of plastic, do not pick up dirt and are very easy to wipe clean inside and out.

  • Regulation

    The PPWR has applied since 12 August 2026. From 2030 it sets reuse targets for certain transport packaging such as plastic crates and pallets; boxes made of cardboard or paperboard are exempt. Whether your shipping is affected depends on format and supply relationship - we are happy to check this with you. Setting up the loop now means you gain experience before customers or regulators ask for it.

Matching packaging

Frequently asked questions

How do I ship plaster casts and 3D scan models safely?

In a dimensionally stable reusable box with padding: the measurement travels to central production protected, and the finished prosthesis, orthosis or insole comes back in the same box.

Does reusable shipping also work for orthosis rentals?

Yes - the aid travels to the patient in the reusable packaging and comes back protected in the same one, instead of in an improvised cardboard box.

Is reusable shipping suitable for store replenishment in medical supply store chains?

Yes: goods travel from the central warehouse to the stores, and the return leg runs either filled or folded flat and bundled - one reusable loop for all locations.

How can you save with reusables?

Our team will be happy to advise you on the benefits of reusable shipping packaging for your shipping loop.

Get advice now