Warehouse Solutions
Corrugated Pick Bins
Designed to Your Needs
Streamline your warehouse picking operations with Lesters’ corrugated pick bins. Designed for speed, accuracy and ease of use, our bins integrate seamlessly with your existing racking and automation systems to deliver faster order fulfilment and reduced operational costs.
Whether you run a 3PL warehouse, an e-commerce fulfilment centre or a manufacturing distribution operation, our corrugated picking bins offer a lightweight, sustainable and cost-effective alternative to traditional rigid plastic trays.
Unlike traditional packaging suppliers, we bring decades of hands-on warehouse and logistics expertise to every bin we design, fully optimised to your business needs.
BRITISH MANUFACTURING
100%
RECYCLABLE
ISO 9001 & 14001
CERTIFIED
CUSTOMISABLE
DESIGN
NEXT DAY
ON STOCK SIZES
What are corrugated pick bins?
Also known as K-bins, shelf bins or warehouse picking trays — and how they work in practice.
Corrugated pick bins (also known as K-bins, shelf bins or warehouse picking trays) are open-top cardboard containers built for organising and retrieving stock within warehouse racking systems. Featuring a lowered front panel for instant visibility and rapid access, they allow pickers to identify and retrieve items at a glance, significantly reducing search time and picking errors.
Delivered flat-pack and assembled in seconds without any tools, tape or staples, our bins are built for warehouses that need to scale quickly and adapt to changing demands.
Key features at a glance
Make an Enquiry about pick bins
Specifications
Single wall and double wall options, standard sizes and fully custom dimensions to fit your racking precisely.
Materials
Double wall — EB flute
32# ECT corrugated material as standard
Kraft for labelling contrast
Dimensions
Load Capacity
Stackable up to 4–5 bins high when empty. Double wall variants safely hold 30–50kg depending on content distribution.
Assembly
Tool-free assembly in under 10 seconds per bin using interlocking tabs and slots. Pre-creased fold lines ensure consistent results every time. Bins can be collapsed and reassembled multiple times.
System Compatibility
Our pick bins are designed to fit 90% of existing metal shelving and pallet racking systems. They integrate with Warehouse Management Systems (WMS) through barcode labels and are fully compatible with RF scanners.
DESIGN & Customisation
Fully customisable to your operation
Every warehouse is different. Our pick bins are available in bespoke dimensions, custom print finishes, pre-applied barcodes and SKU labelling, internal divider configurations and handle options — all engineered to integrate seamlessly with your existing racking, WMS and picking workflow.
Key Benefits
Operational, financial and sustainability gains from switching to corrugated pick bins.
Boost Operational Efficiency
The open-top design with a lowered front panel delivers instant visual identification, reducing search time by 30–40%. Tool-free assembly means 100 bins can be deployed in under 20 minutes, making rapid scaling a reality rather than a logistical headache. Pick-and-sort trolley systems using our bins have been shown to increase picking efficiency by over 40%.
20–30% picking speed increase
Reduce Costs Across the Board
Optimised bin organisation enables faster item retrieval, with modern warehouses reporting picking speed increases of 20–30% after implementing proper bin systems. Flat-pack storage eliminates the cost of warehousing empty containers during quiet periods, and damaged bins cost just pennies to replace compared to plastic alternatives.
60–70% lower logistics cost vs plastic
Sustainable without Compromise
Every corrugated pick bin is 100% recyclable and integrates with your existing commercial cardboard recycling stream. FSC certified options are available to support sustainable forestry goals and meet corporate ESG targets. The lightweight, flat-pack design also reduces transport emissions and cuts logistics costs by 60–70% compared to shipping pre-assembled plastic bins.
FSC certified options
Health, Safety & Ergonomics
Corrugated construction eliminates the injury risk from cracked plastic corners and sharp edges. The open design reduces bending and reaching, promoting better posture for pickers throughout the working day. Stackable empty bins keep warehouse aisles clear, reducing trip hazards. When a bin reaches end of life, simply recycle and replace.
Ergonomic picker design
Where Our Pick Bins Are Used
Trusted across UK warehousing, fulfilment, manufacturing and logistics operations.
3PL & contract logistics
Multi-client warehouse operations requiring flexible, scalable storage. High-volume order picking for multiple brands from a single location. Temporary storage during contract transitions or client onboarding, and staging areas for returns processing and quality control.
E-commerce fulfilment
Small item picking for direct-to-consumer orders across fashion and apparel, electronics accessories, cosmetics and beauty products, books, games and media. Ideal for operations that experience significant seasonal peaks such as Black Friday.
Manufacturing & Distribution
Component storage for production lines, spare parts picking for maintenance operations, automotive parts distribution, hardware and building supplies, and industrial supplies fulfilment. Suitable for both static racking and mobile trolley or cart systems.
Freight forwarding
Consolidation bins for LCL (Less than Container Load) shipments, pick-and-pack operations for multi-destination orders, and temporary storage for transhipment operations.
Why Choose Lesters?
Unlike traditional packaging suppliers, we bring decades of hands-on warehouse and logistics expertise to every pick bin we design.
40+ years of corrugated expertise
Lesters brings over four decades of experience in bespoke corrugated design, with solutions developed for the UK’s leading 3PL providers that cascade down to every customer.
Rapid customisation — 2–3 weeks
Custom sizes, printing and configurations are available with 2–3 week lead times, compared to 6–8 weeks for plastic tooling. We provide free virtual mockups to help you visualise how bins will integrate with your warehouse before you commit.
British Manufacturing
Manufactured in the West Midlands with ISO 9001 certified processes, ensuring dimensional accuracy, structural integrity and shorter lead times than imported alternatives.
Built for volume operations
As one of the UK’s leading large-format corrugated manufacturers, we’re equipped to scale with your operation — from single-site rollouts to national networks.
Stock Availability
Standard sizes held in stock for next-day delivery on orders of up to 500 bins.
Dedicated Support
On-site warehouse audits to determine optimal bin sizing, quantity and placement, with responsive account managers available for ongoing support and reordering.
As one of the UK’s leading large-format, high-volume corrugated manufacturers, we work best with businesses that have a genuine volume requirement. Rather than applying a fixed structure, we work with you to understand your volumes and operational cycle before recommending the most cost-effective route. Get in touch and we’ll quickly confirm whether we’re the right fit.
Discuss your volumesFrequently Asked Questions
Common questions from warehouse managers and operations teams.
In high-intensity environments such as 3PL and e-commerce, expect 6–12 months of active use. In moderate-use distribution or manufacturing settings, typically 12–18 months. Unlike plastic bins that crack suddenly, corrugated bins degrade gradually — giving advance warning for replacement.
Yes. Our double wall EB flute bins are designed for heavy components and can safely hold 30–50kg depending on content distribution. Single wall bins work well for lighter items under 20kg. We have automotive customers using these bins daily for metal parts weighing 15–40kg with excellent results.
Yes, custom sizing is one of our core capabilities. Provide us with your racking dimensions (shelf width, depth and height clearance) and we will design bins that maximise your space utilisation. Custom sizing typically requires 2–3 weeks lead time, and we offer free virtual mockups showing how bins will fit your specific setup.
Ready to optimise your warehouse picking?
As one of the UK’s leading large-format corrugated manufacturers, we work with businesses to find the most effective solution for their operation. Get in touch and we’ll quickly establish whether we’re the right fit for your requirements.
