This article discusses a study on reverse logistics in which a returnable packaging model was developed in order to minimize waste generation and increase the competitiveness of the company studied by reducing costs and resource consumption and minimizing environmental impacts. The objective of this study is to present a case study on reverse flow of returnable packaging to replace a disposable packaging system used by a company located in Joinville, Santa Catarina, Brazil to export machined engine heads to Peterborough, UK. As a result, the returnable packaging model consumed 18.00% less material than the disposable packaging model, reducing costs. Furthermore, the model developed provided greater protection to the products exported and minimized waste generation at the final customer. Other logistic benefits were reduction in the volume occupied and weight of empty packaging during reverse flow and a cycle time of 105 days. Additionally, the unit cost of the returnable packaging was R$ 13.57 per engine head, a satisfactory outcome for the company studied. With regard to environmental performance, the returnable packaging model proved the best alternative since it has less environmental impacts compared to those of the disposable packaging model. The practice of reverse logistics has shown benefits that contribute technically, economically, and environmentally to business sustainability.
