The questions buyers ask

PSi (Packaging Solutions, inc.) designs and builds custom returnable and expendable packaging systems for manufacturers. Based in Milwaukee since 1994, we engineer custom dunnage, returnable packs, bulk bins, dunnage inserts, and corrugated packaging for automotive, powersports, outdoor power, industrial, HVAC, and EV manufacturers.

PSi is headquartered in Milwaukee, Wisconsin. Custom engineering, and manufacturing all happen in one facility. Customers can visit, walk the floor, and meet the engineers working on their program.

PSi was founded in 1994 by Bill Davies and Harry Moulopoulos Sr. The company has been engineering and building custom packaging in Milwaukee for more than 30 years.

PSi serves automotive Tier 1 suppliers, powersports OEMs (motorcycles, snowmobiles, ATVs, side-by-sides, marine), outdoor power equipment manufacturers (lawn, turf, agricultural), industrial equipment, HVAC, premium appliance, and EV-native manufacturers.

PSi is privately held. Co-founders Bill Davies, Harry Moulopoulos Sr., and Malcom Eddy founded the company in 1994. The next generation of leadership, including Benjamin Gover, Harry Moulopoulos Jr., and Dan Davies, runs day-to-day operations today.

Yes. PSi engineers and builds in one Milwaukee facility. Engineering and the build floor sit in the same building, with no hand-offs between design and build, which is what lets us move from concept to first build in days rather than weeks.

Drawings and specifications help, but they are not required. If they are incomplete, we reverse engineer the pack from a sample. Both approaches work.

Many prototypes can be manufactured within one to three weeks after concept approval.

Yes. Reverse-engineering legacy packaging for cost reduction, sustainability gains, or material upgrades is one of our most common engagement types. We can model the existing solution, identify improvement opportunities, and propose alternatives within a few weeks.

Yes. For many new programs, our team will visit your facility to see the part and review the line and handling environment. Photos and drawings are a good start but are never enough on their own.

Returnable makes sense when annual part volume is high (typically 10,000+ units), for high-value and cosmetically sensitive parts, or sustainability commitments require closed-loop systems. 

Expendable is the right answer when volumes are low or one-time, parts ship to end customers rather than closed-loop supplier lanes, logistics include parcel or international freight, or returnable capital costs do not pencil out against freight and damage savings.

Use our Returnable Packaging ROI Calculator. It calculates fleet size, break-even, and five-year total cost of ownership using annual box volume, cost per box, freight cost, damage rate, storage cost, and labor hours. Calculation takes two minutes.

It depends on your part value, volume, freight cost, and damage rate. Most returnable programs break even between 2 and 5 years, with payback driven primarily by freight savings (collapsible return trips) and damage reduction. Run the ROI Calculator for a program-specific estimate.

Yes, and we often do. Many customers have a mix of programs. Returnable for high-volume predictable lanes. Expendable for one-way shipments, parcel, or low-volume runs. We engineer both with the same level of rigor.

We work with polyethylene (PE), polyurethane (PU), cross-linked polyethylene (XLPE), and ESD-rated anti-static foams across the full range of commercial densities. For Class-A automotive applications, we typically specify cross-linked PE or PU in densities tuned to the part weight, contact area, and cosmetic sensitivity.

Yes. We offer EPP molded containers through partner manufacturing. EPP is often the right answer for Class-A automotive and powersports applications where cosmetic protection and durability both matter.

Yes. We work with ESD-rated foams, substrates, and dunnage materials. ESD applications include sensitive electronics, high-voltage components, and any program where electrostatic discharge could damage parts in transit.

For international shipments requiring wood, we use ISPM-15-compliant products. For most other materials, our standard substrates ship internationally without additional certifications. We document compliance for customer audit and customs requirements.

Most are. We select for recyclability when sustainability is a program requirement, including recyclable thermoform substrates, foams with documented recovery pathways, and recovered-fiber corrugated. Material selection is documented per program for customer LCA and ESG reporting.

Reach out on our contact page or call our facility. Live people answer the phone from 7 a.m. to 5 p.m. We will get back to you within a day.

Our fastest documented onboarding was under a week from initial contact to first delivered shipment. Most onboardings take longer because the customer’s internal supplier-qualification process drives the timeline. From our side, we can move as fast as the customer’s paperwork allows.

Minimums vary by program type. For expendable packaging, minimums are typically driven by tooling and material setup costs. For returnable systems, minimums are driven by fleet sizing math. We work with customers across a wide range of program sizes.

Schedule an engineering consultation through the Contact page. 30 to 45 minutes. Sales and engineering on the same call. No pitch. We will help you figure out whether returnable, expendable, or some combination is the right call before you commit to anything.

Yes. Most of our customers operate under mutual NDA from the initial conversation. We have decades of experience handling confidential customer information across automotive, powersports, EV, lawn and garden, art, and other sensitive industries.

Yes. Most of our automotive work runs through Tier 1 suppliers managing programs across multiple OEM customers. We engineer packaging that meets the standards of various OEMs. We also have partner suppliers who are specialists, so if your program falls outside our core work, let us know and we will point you in the right direction.

Yes, we handle battery-related packaging, returnable and expendable packaging for battery components.  If you have a battery packaging need, reach out, and we will determine if your need fits our capabilities.

Yes. Multi-division programs are one of our specialties. We currently work across multiple divisions of major outdoor power, automotive, and industrial manufacturers, and institutional knowledge from one division carries forward to the next.

Yes. We engineer protective and returnable packaging for medical device and equipment programs as part of our healthcare and life sciences work. The approach is the same one we bring to other precision industries: engineering the pack around your part to protect it through transport, handling, and line-side use.