Digital Returnable Management Powered by AI
Automated counting of reusable containers – ideal for operations using EPS reusable crates.
Introduction
Efficient returnable management is becoming increasingly important in modern logistics. Reusable containers are a central component of many supply chains – especially the widely used EPS reusable crates. However, counting and documenting these assets is often still done manually, which is time-consuming and prone to errors. Different container types, high circulation volumes and varying process conditions make accurate and consistent recording difficult in day-to-day operations.
With Edge.Count, this entire process becomes fully digital. The AI automatically detects reusable containers, counts them reliably and documents every step in real time – regardless of contamination, stack height or environmental conditions. This creates a faster, more transparent and error-free returnable workflow that helps companies efficiently manage their reusable loops and sustainably optimise the handling of EPS crates.
Challenges in Today’s Returnable Management
In day-to-day returnable management, the recording of reusable containers – including widely used EPS reusable crates – is still often carried out manually. Quantities are estimated by visual inspection, written down on paper or later transferred into systems. This results in time loss, process interruptions and a high administrative workload.
Manual counting processes are also prone to inaccuracies. Different stack heights, contamination, high circulation volumes and changing personnel often lead to inconsistent results. Especially during peak periods, containers may be overlooked or counted incorrectly.
Another common bottleneck arises 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 included. The counting then has to be repeated – a process that costs time and adds stress to the workforce.
Paper-based processes also carry the risk of missing information: notes become illegible, quantities are transferred incorrectly or documents get lost entirely. This leads to inventory discrepancies, follow-up clarifications and unnecessary coordination loops between logistics, warehouse and administration.
Without digital support, it is also difficult to understand how many reusable containers are actually handled or how many units circulate on a daily basis. The lack of central transparency makes it challenging to manage the entire returnable loop – especially with high volumes and frequent deliveries involving EPS crates.
Typical Challenges in Returnable Management
- Manual counting leads to inconsistent results and high error rates
- Paper-based documentation causes media disruptions, extra work and unclear records
- High circulation volumes and varying stack heights make accurate quantity recording difficult
- Mixed container types and sizes (e.g., EPS reusable crates) require time-consuming manual recounts
- Lack of transparency about actual inventories, movements and daily circulation volumes
- No central digital overview for complaints, discrepancies or clarification processes
Edge.Count: Digital and AI-Powered Detection of Reusable Containers
With Edge.Count, you can fully digitize your returnable management and eliminate the weaknesses of manual counting processes. The mobile app enables fast, precise and AI-powered recording of reusable containers – including EPS reusable crates – directly at the point where they occur. No paper lists, no recounting and no additional administrative effort.
The AI automatically detects the number of containers in the captured image – regardless of stack heights, contamination or mixed container types. As a result, inaccurate visual checks, miscounted mixed stacks and inconsistent manual assessments are completely eliminated.
All recorded quantities are digitally documented in real time and instantly stored in the cloud. Incomplete counts, missing information or lost paper documents become a thing of the past. Discrepancies and claims can be clearly identified at any time using the stored images.
Compared to paper-based processes, Edge.Count provides complete transparency over daily circulation volumes, inventories and counting histories. This gives companies a reliable data foundation for managing their reusable and EPS container cycles – precise, digital and accessible at any time.
Advantages Over Manual Counting Processes
- Automatic quantity counting powered by AI – precise and independent of stack heights or mixed container types.
- No paper documentation – all counts are recorded digitally, stored securely and available instantly.
- Significantly fewer errors thanks to automated AI detection instead of manual visual inspection.
- Immediate data availability in the cloud – counts, images and histories accessible in real time.
- Time savings in daily operations – faster processing of large volumes without manual recounting.
- Full transparency over reusable containers, circulation volumes and EPS crates – always traceable.
- Image-based documentation for every count provides clear evidence for discrepancies and claims.
- Reduced workload for staff thanks to easy app usage and the elimination of manual tasks.
Edge.Trace: The Central Platform for Your Digital Returnable Management
With Edge.Trace, you have a powerful platform that centrally consolidates and clearly visualizes all counts captured with the Edge.Count app. All reusable containers – including EPS reusable crates – are digitally documented, versioned and stored in a clear historical log. This creates a complete, audit-proof and always accessible returnable record.
The platform allows you to easily identify quantity trends, circulation volumes, deviations and recurring patterns. This significantly reduces administrative workload: no Excel sheets, no handwritten notes, no lost documents. All data is available in real time – prepared for logistics, controlling, partners and suppliers.
Edge.Trace serves as a central track-and-trace solution for reusable workflows and provides a reliable data foundation for decision-making in returnable management. From individual counting events to cross-location evaluations, all information is available in a structured and clearly visualized manner.
Digital Analysis & Central Management of Your Returnables
- Central storage of all counts from Edge.Count, including complete image documentation.
- Full transparency over reusable containers, EPS crates and daily circulation volumes.
- Automatic evaluation of trends, deviations and recurring patterns.
- Export functions for internal processes, partners or suppliers – without manual rework.
- Cross-location overview: all returnable movements consolidated on one platform.
- Audit-proof storage of all images, counting events and quantity histories.
This means your returnable management is not only digitally documented, but fully centralized, transparent and data-driven.
Use Cases and Conclusion
Edge.Count and the central platform Edge.Trace are ideal wherever reusable containers – including EPS reusable crates – need to be recorded, counted and documented on a regular basis. Especially in environments with high circulation volumes or frequent deliveries, the combination of mobile AI counting and centralized data analysis reduces manual effort, minimizes errors and enables transparent, digital returnable management.
- Food retail and fresh logistics
- Central distribution and warehouse locations with EPS returnable cycles
- Production facilities with recurring container returns
- Supplier and partner logistics with mandatory quantity documentation
- Locations with manual counting workloads or paper-based returnable processes
In summary, the combination of Edge.Count and Edge.Trace enables a modern, AI-powered and fully digital returnable management workflow. Quantities are captured faster and more accurately, data is documented automatically and processes are sustainably streamlined. Companies benefit from significantly reduced manual effort, less rework and maximum transparency throughout their reusable asset 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 automatically counting reusable containers, including EPS reusable crates. The app replaces manual counting, paper lists and visual inspection, enabling fast, precise and fully digital capture of returnable assets.
How does counting work with the app?
The user takes a photo or uses the camera function of the handheld device. The AI automatically detects the number of containers – regardless of stack height, contamination or mixed container types. Results are stored digitally in real time.
Which container types can Edge.Count recognize?
Edge.Count can recognize a wide range of reusable container types, including EPS crates, folding crates, plastic trays, boxes and custom company-specific containers, as long as they are trained in the system.
How does Edge.Trace support returnable management?
Edge.Trace is the central platform where all counts are stored, visualized and analyzed. It provides transparency over circulation volumes, histories, deviations and multi-site processes – entirely without paper or Excel.
Are images of the counts stored?
Yes. Each count is stored with an image. This supports claims, audits, clarifications and provides a reliable proof for partners and suppliers.
Do I need an internet connection to use the app?
Counts can also be performed offline. Once 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 mobile devices and common smartphones used in logistics. The app is optimized for daily operational workloads.
How accurate is the AI detection?
The recognition models are trained on thousands of real-world images and achieve very high accuracy in practice – even with contamination, changing light conditions or mixed container stacks.
Can multiple sites be connected?
Yes. Edge.Trace supports any number of sites. All counts flow into a central dashboard and can be filtered, segmented and analyzed – ideal for larger companies or multi-site operations.
Is the solution suitable for EPS returnable cycles?
Absolutely. Edge.Count and Edge.Trace are ideal for companies that regularly handle EPS reusable containers and need to document their quantity flows reliably.
How secure is the stored data?
All data is processed in compliance with GDPR. Storage is encrypted – either locally or in the cloud. Permission-based access ensures only authorized users 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 unlimitedly. The Edge.Trace platform can be set up within a few hours.
Does Edge.Count support other reusable container types?
Yes. Edge.Count can detect a wide range of reusable containers once they have been trained in the system. This includes:
- IFCO reusable crates
- KLTs / small load carriers
- Bakery crates
- Meat crates / E2 crates
- Plastic trays and folding crates
- Custom or company-specific containers
New container types can be added and trained at any time – the AI adapts flexibly to your operational processes.
Can Edge.Count also detect load carriers (pallets, roll cages, etc.)?
Yes. In addition to reusable containers, Edge.Count can detect and classify various load carriers once trained. This includes:
- Euro pallets (EPAL / EUR)
- CHEP pallets (blue)
- LPR pallets (red)
- Plastic pallets / H1 pallets
- Mesh boxes / steel cage boxes
- Roll cages / roll containers / trolleys
- Dolly systems and rolling boards
- Custom load carriers from production or warehouse logistics
New load carriers can be added at any time – the AI can be trained to match your specific process requirements.
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