The Automotive & Returnables Division offers timely and efficient production of custom-built samples and prototypes, which are constructed from a wide variety of materials. Our modern lab equipment fabricates a design for a specific application, eliminating tooling costs. Benefits of this service include:

  • Pre-shipment testing
  • Ensuring proper fit, form, and function
  • Allowing for design revisions
  • Identifying past problem history (problem prevention)
  • Implementing real-world packaging use and shipments

Returnables Manufacturing

Whether your packaging needs require plastics, foams, fabrics, racking or all of the above, The Royal Group provides the solutions you need.

Plastics – TRG Returnables converts corrugated plastic in house. We offer our customers:

  • Totes and Dunnages – In a variety of colors and materials
  • Class A Surface protection – Spunbon, Brushfab, Tyvek Laminates
  • Material thicknesses – 2 to 10 mm

Foam – TRG Returnables converts foam materials in house. We offer our customers:

  • Class A & Class B Surface – Protective packaging using Crosslink, EPE, EPP, and EPS
  • Material Densities – 1 to 10 pounds

Fabric – We manufacture custom dunnage using:

  • Spunbond
  • Brush-fab (brushnylon)
  • Tissue-Lam
  • Tyvek
  • Vinyl
  • Autoguard & Softshield Comparables

TRG Returnables hand-assembles fabric dunnages and bag systems into a variety of outer containers. Working closely with the materials manufacturers and furnishing into reusable container systems is another way we add value to your packaging program.

TAP Racks – TRG Returnables designs and constructs TAP (Temporary/Adjustable Pipe) Racking systems, which embrace lean concepts by considering space, travel, and ergonomic principles. We create:

  • WIP Carts
  • Low Racks
  • Tables
  • Part Racks

From concept to production, we work with you to plan and build an organized, efficient, ergonomic, and profitable working environment.

Expendable Packaging

We can provide an expendable – in a variety of materials and board grades – to complement every returnables design we create for you, including solutions for:

  • Export Packs
  • Service/Dealer Packs
  • Returnables Back-Up Packs


Your company needs to make every dollar count.  We understand how integral a packaging program that performs effectively is to ensuring your operations run smoothly. Solutions we provide include:

  • Returnables Tote Rent to Own Programs – Close the barrier between capital expense approval and having the packaging you need to protect your goods and your cash flow
  • Tote Return Programs – Receive credit for  viable totes that are obsolete to your system, but still usable for other clients

Container Management

Our goal is to make managing your packaging program simple. We offer container management solutions for:

  • Space Limitations
  • Obsolescence
  • Repairs
  • Future Container Reuse (Cleaning and Storage)

Minority Supply Partner/Sources

Our Minority Business Enterprise (MBE) supplier relationships allow us to offer built-in solutions for managing your packaging supply chain. We can assist your company in minority sourcing for a variety of product categories, including:

  • Packaging Design
  • Returnables Packaging
  • Expendable Packaging
  • Foam Fabrication
  • Packaging Fulfillment
  • Container Management