Why reuse usually comes out ahead
Making a new tote means producing an HDPE bottle, a galvanized steel cage and a pallet. Reusing a sound tote avoids manufacturing those parts for that job. Cleaning takes water, energy and chemicals, and transport adds fuel, but published life-cycle studies of reusable packaging generally find reuse has a lower footprint than single-use when the container makes several trips.
When a tote can't be reused, recycling the HDPE and scrapping the steel cage recovers material that would otherwise be landfilled.