Custom Warehouse Picking Bins: Matching Bin Design to Shelving and Picking Requirements

In warehouse operations, picking bins are more than containers for storing products. Their dimensions, openings and internal arrangements need to work with the shelving system and the way goods are handled.

For businesses sourcing custom warehouse picking bins, the challenge is not necessarily finding a suitable material. Many procurement teams already have established specifications and storage requirements. The more important question is how those requirements translate into a practical bin design.

Corrugated Plastic Australia offers custom polypropylene (PP) corrugated picking bins with different dimensions, structural features and material specifications. This article explores the main design considerations for businesses planning a customised warehouse storage solution.

1. Shelving Compatibility: Start with the Storage System

A picking bin needs to fit the space in which it will be used. However, matching the external dimensions to the available shelf space is only the starting point.

Buyers should also consider how the bin will be positioned, accessed and removed.

For example, a bin that fits the full depth of a shelf may provide substantial storage space, but its contents could be difficult to reach if workers need frequent access to items at the back.

Similarly, a tall container may fit within the available shelf height but leave insufficient clearance for comfortable picking.

Relevant measurements include:

• Shelf width, depth and usable height

• External and internal bin dimensions

• Clearance for inserting or removing the bin

• Access requirements when bins are positioned next to or above one another

• Space needed for handles, labels or other attachments

Corrugated Plastic Australia's Custom Corrugated Plastic Picking Bin range lists fully customisable dimensions to suit shelves and racks, with a stated dimensional tolerance of ±2 mm.

For businesses using existing storage systems, providing shelf drawings or detailed measurements can help establish suitable dimensions before manufacturing.

2. Picking Access: Consider How Products Are Retrieved

The position and shape of a bin opening can influence how workers interact with stored products.

An open-front or slanted design may be useful when items need to be accessed frequently without removing the entire container from the shelf.

However, an opening should not be considered independently of the stored products.

For example, a large front opening may provide convenient access to small components, while products that are easily displaced may require a different retaining structure.

Buyers should consider the size and shape of the goods, the expected picking frequency and the position of the bin within the storage system.

A warehouse may also use different bin configurations across its operations. Frequently retrieved components may benefit from accessible front openings, while other goods may require greater containment during storage or movement.

For an introduction to the different types of corrugated plastic picking boxes and slanted bins, see our existing warehouse picking bins guide.

3. Internal Organisation: Making Use of Custom Features

Customisation does not always require changing the entire bin structure. In some cases, adjusting the internal layout or identification features may be sufficient.

Corrugated Plastic Australia's picking bin product information includes options such as internal dividers, hand holes, reinforced corners, edge sealing and printed identification.

Each feature addresses a different requirement.

Internal dividers may help separate product categories or prevent smaller components from becoming mixed.

Hand holes can support manual handling, although their placement should be considered alongside the weight of the contents and the bin's structure.

Labels and printed identifiers can help distinguish storage locations and product categories.

Reinforced edges and corners may be considered where additional structural support is required.

These options should be selected according to the intended application, rather than added automatically.

For example, a divider may improve organisation but also reduce the usable space available for larger products. A handle opening may make a bin easier to lift while changing the design of its side wall.

Understanding these trade-offs helps buyers identify which features are necessary.

4. Material Specifications and Structural Requirements

The design of a picking bin also needs to account for the material from which it is manufactured.

Corrugated Plastic Australia's Custom Corrugated Plastic Picking Bin range includes the following specifications and customisation options:

Specification	Published Product Information
Material	Polypropylene (PP)
Thickness	3–12 mm
Common thicknesses	3, 4 and 5 mm
Sheet weight (GSM)	250–2300 GSM
Bin dimensions	Customisable to shelves and racks
Load capacity	10–30 kg per bin, depending on design
Structural options	Edge sealing, reinforced corners and hand holes

These figures describe the published product range, not a single standard bin configuration.

In particular, the stated load capacity should not be treated as a guarantee for every combination of thickness, dimensions and structural features.

A bin's performance can depend on its construction, contents and loading conditions.

For buyers planning stacked storage, the weight of the contents is only one consideration. The number of stacked levels, distribution of loads and support provided by the shelving system may also need to be evaluated.

Thickness and GSM are useful specifications, but neither independently establishes the performance of a finished picking bin.

Where load-bearing performance is important, the relevant configuration and testing requirements should be confirmed with the manufacturer.

5. From Storage Requirements to Custom Manufacturing

Once the main requirements are established, buyers can prepare a more detailed product specification.

For established warehouse operations, this may involve adapting an existing picking bin design to fit particular shelving dimensions or product categories.

For new storage systems, additional design development or prototyping may be appropriate.

Before confirming a custom order, it is useful to establish the following information:

Design Area	Information to Confirm
Shelving	Usable dimensions and clearance
Contents	Product size, shape and weight
Access	Opening position and picking requirements
Structure	Stacking arrangement and load conditions
Material	Thickness, GSM and any special requirements
Customisation	Dividers, handles, labels or reinforcements
Purchasing	Estimated quantity and delivery destination

Corrugated Plastic Australia provides custom manufacturing services and design support for corrugated plastic products.

When the required configuration is not yet finalised, discussing these details early can help identify potential design questions before bulk production.

Choosing a Picking Bin That Fits the Workflow

There is no single picking bin design that is suitable for every warehouse.

A configuration that works well for frequently accessed small components may not be appropriate for larger items, stacked storage or containers that must be moved regularly.

The purpose of customisation is to match the bin's dimensions, structure and features to the actual requirements of the operation.

For procurement teams, clear specifications provide a useful foundation for discussing manufacturing options and evaluating whether a proposed design is suitable.

Looking for Custom Warehouse Picking Bins?

Corrugated Plastic Australia supplies custom PP corrugated picking bins for warehouse and logistics applications.

If you have existing shelf dimensions, product specifications or drawings, share them with our team along with your estimated order quantity.

Request a Quote to discuss suitable designs and manufacturing options for your warehouse.