The problem

Tote boxes and picking trays are essential for kitting, line feeding, and internal logistics in electronics facilities. These items are frequently moved, stacked, and handled by operators, creating repeated opportunities for static charge generation on insulating plastic surfaces.

Carbon-filled ESD totes are commonly used as a solution, but they often suffer from brittleness, cracking at corners, and gradual loss of ESD performance as the material wears.

The substrate

Injection-moulded polypropylene or polyethylene tote boxes and picking trays, typically designed for stacking, nesting, and repeated handling.

Why replacement was not viable

• High cost of carbon-filled ESD totes compared to standard plastic versions
• Frequent cracking and corner damage in conductive plastic trays
• Large installed base across production and warehouse areas
• Sustainability initiatives favouring reuse over disposal

The ProShieldESD solution

ProShieldESD was applied as a thin, uniform coating to the internal and external surfaces of tote boxes and picking trays. The two-part coating adheres strongly to plastic substrates while maintaining dimensional accuracy.

The coating delivers controlled, humidity-independent ESD behaviour without compromising stackability, nesting, or load capacity.

Performance outcome

• Surface resistance maintained within the ESD dissipative range
• Uniform charge dissipation across trays and totes
• Improved mechanical durability compared to conductive plastics
• Stable performance under repeated handling and stacking

Standards alignment

The converted tote boxes and picking trays support ESD control programs aligned with IEC 61340 and ANSI/ESD S20.20 requirements when integrated into grounded material handling systems.

Key benefits

• Extends usable life of existing tote boxes and trays
• Reduces breakage and replacement cost
• Supports sustainable material handling practices
• Easy to repair or recoat if damaged