53 Percent Labor Savings for Grocers Using Tosca Reusable Plastic Containers (RPCs)

Results of Time & Motion Study by 3rd Party Industrial Engineering Firm

ATLANTA, Ga. — Tosca, an innovator in reusable packaging and supply chain solutions for perishables, has announced the results of a Time and Motion Study for eggs. A third-party industrial engineering firm, Advantage Consulting, was commissioned by Tosca to conduct the study evaluating the impact of transport packaging solutions on store labor. The study compared the time it takes to stock and manage egg displays in a grocery store using traditional one-way corrugated shipping boxes versus Tosca’s Reusable Plastic Containers (RPCs).*

The methodology for comparison analyzed the multi-step process for managing the egg department, including pulling egg cases from the cooler, stocking and rotating cartons, disposing of packaging and removing damaged eggs.

Findings from the Time and Motion Study show:

  • It takes less than half the time to stock an egg display using retail-ready RPCs instead of corrugated. On average, in an 8-foot display case, RPCs stock and rotate product in 10 minutes versus 21 minutes for corrugated packaging.
  • Taking advantage of timesaving RPCs, retailers will see a 53 percent reduction in labor to manage the egg category.
  • Using RPCs, each store will save five days and 16 hours in labor each year. This labor can be reallocated to other tasks.**

Additionally, the study found that when using corrugated, removing egg cartons from boxes and stacking them in the display case has a significant impact on stocking time (35 percent) while rotation of product is another important factor in stocking time (24 percent).

With Tosca’s retail-ready solution, eggs can be displayed directly in its custom-designed RPCs, eliminating the time-consuming tasks of removing, stacking, and rotating egg cartons. Tosca’s unique one-step SmartWallTM design simplifies restocking and saves labor by allowing employees to place the container directly in the case and drop the front wall for display in one easy motion.

Additionally, it’s easier and faster to rotate merchandise when cartons are in RPCs versus stacked individually.  Managing the egg display with corrugated means handling individual cartons for rotating stock versus RPCs that move 24 cartons at one time. RPCs can be removed from the display case, newer product in RPCs can be added to the display, and then the RPC with the earliest expiration date can be placed in front.

“We know that retailers are looking for a better way to identify cost and labor savings, improve supply chain efficiency and protect the product quality of perishables,” said Eric Frank, president, and CEO of Tosca. “This study helps validate that there is a better way to move eggs safely and efficiently from source to shelf. RPCs not only are easier and faster to stock but also help reduce shrink by offering the best protection available for fragile eggs.”

About Tosca

Tosca (www.toscaltd.com) is a leading provider of reusable packaging and supply chain solutions across a diverse range of markets including eggs, case-ready meat, poultry, produce, and cheese. It states that its proven RPC system is a smarter way to move fresh product safely from source to shelf, substantially reducing shrink and labor cost, maintaining product quality, and optimizing overall supply chain efficiency for retailers, growers, and suppliers. To learn more, visit www.toscaltd.com.

* The Tosca Time and Motion Study was conducted in regional grocery stores in the Midwest in 2018. Over two separate one-week periods a third-party engineer traveled to each store and studied the time it takes to stock and rotate eggs in a display cooler, the first week using traditional corrugated shipping boxes and the second week using reusable plastic containers (RPCs).

**Based on stocking an 8-foot display twice a day.