Where Does Your Money Go? Hidden Logistics Costs You May Not Even Be Aware Of.

How many euros are just sitting idle in your yard in damaged or lost packaging?

This is precisely the question that often comes up during discussions about the tracking of RTI packaging, or when there is a call to streamline logistics at a manufacturing facility. Many companies view costs solely in terms of the prices of raw materials, energy, or labor. However, significant financial resources remain hidden in supporting logistics operations—specifically in the reverse logistics of reusable transport packaging (RTI—Returnable Transport Items).

Plastic crates, pallets, and large metal transport structures (stillage) are critical to the smooth operation of a production line. If they aren’t in the right place at the right time, both production and logistics come to a standstill. A euro here, a euro there for packaging, some “downtime” costs for the truck, production stoppages… It all adds up, doesn’t it?

The Most Common Problems with RTI Records in Slovakia

With our customers—particularly manufacturing and logistics companies (mostly Tier 1/2)—we consistently encounter the same barriers:

  • Manual counting and paper records: Pallet operators count “by eye,” which leads to a high error rate.
  • Loss of traceability among customers: Companies do not know exactly how many packages were sent to customers and how many were actually returned.
  • Blind investments: Due to a lack of oversight, new RTI packaging is purchased unnecessarily, while old packaging ties up capital in warehouses or goes missing.
  • Lack of knowledge regarding condition and wear and tear: There is no overview of damaged items or of when the packaging was last inspected, if at all.
  • Delays for Forklift Operators: Constantly covering old barcodes with new labels slows down the shipping process. Forklift operators must scan the codes, which often requires them to “jump out” of the forklift itself.

Solution: Automatic tracking via RFID and ReturnCheck

At BARTECH SLOVAKIA, we eliminate these inefficiencies using contactless RFID technology and our software RETURN CHECK.

You attach a durable RFID tag to the package—ideally only once (or until it is manually damaged, which does not happen often). The system then automatically records it every time it passes through the shipping gate—without requiring any intervention from the forklift operator or manual scanning. In a fraction of a second, you can track the bulk movement of dozens of crates or pallets at once.

How will implementing ReturnCheck improve your efficiency?

  • Fully automated and error-free: No more manual data entry. RFID scanning works reliably and without human error.
  • Instant overview of location: You know exactly how many packages have been sent to each customer and how many are due to be returned to you.
  • No more unnecessary purchases: You optimize your packaging turnover and buy new items only when it’s truly necessary.
  • Transparent History: The system tracks wear and tear and repair cycles, so you eliminate the risk of damaged packaging entering production.
  • Easy integration: We’re happy to integrate the RETURN CHECK software with your existing MES, WMS, or ERP systems, including SAP, Oracle, and others.

Stop hidden losses in logistics and turn the chaos of returnable packaging into clear data.

Are you interested in RFID but not sure how to implement it in your company?

Please contact us at obchod@bartech.sk or via the Contact Form on our website .