Digital Returnable Container Management with AI Counting
Automatic counting of reusable containers, beverage crates, pallets and much more
Introduction
Efficient returnable container management is becoming increasingly important in today's logistics. Reusable containers are a central component of the product cycle – especially the EPS reusable crates used in many companies. Yet counting and documentation are often still done manually, which is time-consuming and error-prone. Different container types, large volumes and varying process conditions make precise and consistent capture difficult in day-to-day operations.
Edge.Count fully digitizes this process. The AI automatically recognizes reusable containers, counts them reliably and documents every step in real time – regardless of soiling, stack height or environmental influences. This creates a faster, more transparent and error-free returnable container process that helps companies efficiently manage their reusable cycles and sustainably optimize EPS container management.
Challenges in Today's Returnable Container Management
In daily returnable container management, the capture of reusable containers – including the widely used EPS reusable crates – is often still performed manually. Quantities are estimated by visual inspection, documented on paper or later transferred to systems. This leads to time loss, media breaks and high administrative effort.
Manual counting processes are also prone to inaccuracies. Different stack heights, soiling, large volumes and changing staff quickly lead to inconsistent results. Especially during peak times, containers can be overlooked or miscounted.
Another common bottleneck occurs when different container types or sizes are used simultaneously. In mixed stacks, it is often not immediately clear how many units of each category are actually present. The count must then be repeated – a process that costs time and adds extra burden on staff.
In addition, paper-based processes can lack important information: Notes become illegible, quantities are transferred incorrectly or documents are lost entirely. This results in inventory errors, follow-up questions and unnecessary coordination loops between logistics, warehouse and administration.
Without digital support, it is also difficult to trace how many reusable containers were actually handled or what volumes are in circulation daily. A lack of central transparency makes it harder to manage the entire reusable cycle – especially with large volumes and recurring deliveries with EPS containers.
Typical Challenges in Returnable Container Management
Edge.Count: Digital and AI-Powered Capture of Reusable Containers
With Edge.Count, you digitize your entire returnable container management and eliminate the weaknesses of manual counting processes. The mobile app enables fast, precise and AI-powered capture of reusable containers – including EPS reusable crates – right where they occur. No paper lists, no recounts and no additional administrative effort.
The AI automatically recognizes the number of containers in the captured image – regardless of stack heights, soiling or mixed container types. This eliminates faulty visual inspections, miscounted mixed stacks and inconsistent staff assessments entirely.
All captured quantities are documented digitally in real time and stored immediately in the cloud. Incomplete counts, missing information or lost paper documents are a thing of the past. Discrepancies and claims can be traced clearly at any time using the stored images.
Unlike paper-based processes, Edge.Count offers complete transparency over daily volumes, inventories and count histories. Companies gain a reliable data foundation for their reusable and EPS container cycles – precise, digital and available at any time.
Advantages over Manual Counting Processes
Edge.Trace: The Central Platform for Your Digital Returnable Container Management
Edge.Trace provides a powerful platform that centrally consolidates and transparently displays all counts captured with the Edge.Count app. All reusable containers – including EPS reusable crates – are documented digitally, versioned and stored in a clear history. This creates a complete, audit-proof and always retrievable returnable container protocol.
The platform makes it easy to identify volume trends, circulation volumes, discrepancies and recurring patterns. This significantly reduces administrative effort: No Excel lists, no handwritten records, no lost documents. All data is available live – prepared for logistics, controlling, partners and suppliers.
Edge.Trace serves as a central track-and-trace solution for reusable processes and creates a real data foundation for decisions in returnable container management. From individual counting operations to cross-site evaluations, all information is available in a structured and visually understandable format.
Digital Evaluation & Central Management of Your Returnables
Application Areas and Conclusion
Edge.Count and the central Edge.Trace platform are suitable wherever reusable containers – including EPS reusable crates – need to be regularly captured, counted and documented. Especially in areas with high volumes or frequent deliveries, the combination of mobile AI counting and central data evaluation results in significantly less manual effort, fewer errors and transparent, digital returnable container management.
In summary, the combination of Edge.Count and Edge.Trace enables modern, AI-powered and fully digital returnable container management. Quantities are captured faster and more precisely, data is documented automatically and processes are sustainably simplified. Companies benefit from a significant reduction in manual tasks, less rework and maximum transparency in their reusable cycle.
Frequently Asked Questions about Edge.Count & Edge.Trace
What is Edge.Count and what is it used for? +
Edge.Count is an AI-powered app for automatic counting of reusable containers, including EPS reusable crates. The app replaces manual counts, paper lists and visual inspections and ensures fast, precise and fully digital capture.
How does counting work with the app? +
The user takes a photo or uses the camera function of the handheld device. The AI automatically recognizes the number of containers – regardless of stack heights, soiling or mixed container types. Results are saved digitally immediately.
Which container types can Edge.Count recognize? +
Edge.Count recognizes various reusable container types, including EPS crates, collapsible crates, plastic trays, boxes or company-specific special containers, provided they have been trained in the model.
How does Edge.Trace help in returnable container management? +
Edge.Trace is the central platform where all counts are stored, visualized and evaluated. It provides transparency over volumes, histories, discrepancies and cross-site processes – completely without paper and Excel.
Are the images of the counts stored? +
Yes. Every count is stored including the image. This helps with claims, clarification cases, audits and provides clear verification for partners or suppliers.
Do you need internet to use the app? +
Counts can also be captured offline. As soon as a connection is available, the app automatically synchronizes all data with Edge.Trace.
Which devices are supported? +
Edge.Count runs on Android-based handheld devices, industrial handhelds and standard smartphones used in logistics. The app is optimized for high demands in daily use.
How reliable is the AI recognition? +
The recognition models were trained on thousands of real images and achieve very high recognition rates in practice – even with soiling, changing light conditions or mixed container stacks.
Can multiple sites be connected? +
Yes. Edge.Trace supports any number of sites. All counts are consolidated centrally and can be filtered, segmented and evaluated – ideal for larger companies or groups.
Is the solution suitable for EPS returnable container cycles? +
Absolutely. Edge.Count and Edge.Trace are ideal for companies that regularly have EPS reusable containers in circulation and need to reliably document their volume flows.
How secure is the stored data? +
All data is processed in compliance with GDPR. Storage is encrypted – optionally locally or in the cloud. Access restrictions and role models ensure that only authorized persons can view data.
How much setup effort is required? +
The app is ready to use immediately. Container models are trained once and can then be used indefinitely. The Edge.Trace platform is set up within a few hours.
Does Edge.Count also support other reusable containers? +
Yes. Edge.Count can recognize a wide variety of reusable containers, provided they have been trained in the system once. These include:
- IFCO reusable crates
- RPCs / small load carriers
- Bakery crates
- Meat crates / E2 crates
- Plastic trays and collapsible crates
- Special and custom containers
New container types can be added and trained at any time – the AI adapts flexibly to your processes.
Can load carriers also be recognized? +
Yes. In addition to reusable containers, Edge.Count can also recognize, classify and document various load carriers, provided they have been trained in the system. These include:
- Euro pallets (EPAL / EUR)
- CHEP pallets (blue)
- LPR pallets (red)
- Plastic pallets / H1 pallets
- Mesh boxes / steel mesh boxes (DB mesh box)
- Roll cages / roll containers / trolleys
- Dolly systems and roll boards
- Special load carriers from production and warehouse logistics
New load carriers can be added at any time – the AI can be flexibly trained to your individual process requirements.
Ready for digital returnable container management?
Find out in a non-binding demo how Edge.Count and Edge.Trace can automate your reusable processes and take your returnable container management to the next level.