Milan, 4 December 2025 – Northern Italy’s regional supermarket chain Iperal has taken a major step forward in fresh-food logistics with the introduction of Tosca’s automation-ready reusable plastic crates (RPCs). The transition follows the opening of the retailer’s new Fresh Food Centre in Giussano (MB), a 50,000 m² hub designed to consolidate fresh operations and support the company’s expanding Fatto da Noi (“Made by Us”) product range.
Built with full automation, renewable energy supplied by 4,300 solar panels, and a design centered on food quality and efficiency, the new facility prompted Iperal to reassess a longstanding challenge: its dependence on single-use and mixed-material crates for produce distribution. For years, cardboard, plastic, and wooden crates created large waste streams, contributed to pallet instability, and made it difficult to maintain a consistent appearance across stores. With the advanced Giussano site coming online, Iperal saw the moment as an opportunity to shift to a standardized, circular system that could support automation and reduce environmental impact.
Tosca RPCs Deliver Standardization, Durability, and Retail-Ready Presentation
To support this transition, Iperal adopted Tosca’s Wood Look reusable plastic crates and bins. The retailer selected 60×40 and 30×40 footprints in multiple heights along with large-format bins for upstream transport. These RPCs combine the familiar aesthetic of traditional wooden displays with the durability, hygiene, and repeat-use performance of engineered plastic.
The reusable crates move through Tosca’s pooling network, where each unit is collected, washed, inspected, and redeployed. This closed-loop approach eliminates the waste and inconsistency inherent in disposable packaging and supports a unified presentation across Iperal’s 56 stores.
“This partnership shows how reusable packaging unlocks operational and environmental value,” said Gian Paolo Mezzanotte, Managing Director – Italy, France, Spain at Tosca. “By introducing a standardized, reusable system, we’ve helped simplify logistics, enhance product quality, and support Iperal’s long-term sustainability goals.”
For readers seeking more information on Tosca’s reusable systems, visit the Tosca Reusable Packaging Company Hub.
Improved Efficiency, Automation Performance, and Waste Reduction
Since implementing Tosca’s RPCs, Iperal has reported measurable improvements across its fresh supply chain:
- Greater pallet stability thanks to standardized crate footprints and uniform construction.
- Smoother automated processing at the new Fresh Food Centre, with fewer stoppages and better line consistency.
- Reduced packaging waste as disposable crates are removed from the system.
- Improved product protection during transport, supporting Iperal’s emphasis on quality.
According to Lorenzo Zecca, Iperal’s Supply Chain Director, the RPCs integrate seamlessly with the automated systems at the Giussano facility.
“Tosca’s automation-ready RPCs fit seamlessly into our lines. We’ve seen faster throughput, fewer stops, and more consistent performance overall. The durability and uniformity of the RPCs have reduced disruptions, improving reliability across our supply chains.”
In-store, fresh products now appear in clean, uniform, wood-look RPCs that reinforce Iperal’s focus on quality and presentation. The improved durability of the crates has also contributed to a reduction in product loss.
Readers can explore more applications of reusable systems in grocery environments through the Reusable Packaging for Retail Hub.
Strengthening a Circular, Low-Carbon Fresh Supply Chain
The shift to Tosca’s reusable packaging supports Iperal’s wider sustainability initiatives, including reductions in waste and improved resource efficiency. While full CO₂ and waste-reduction metrics are still being measured, the company notes visible benefits through streamlined operations, cleaner workflow, and a more consistent replenishment process.
The success of the rollout has encouraged Iperal to extend Tosca’s reusable assets to additional suppliers in Spain and the Netherlands. The retailer is also evaluating opportunities to further improve in-store replenishment by leveraging the same standardized crate architecture.
Iperal describes its collaboration with Tosca as “constructive, productive, and efficient,” viewing the partnership as a core element in building a modern, low-waste fresh supply chain.
About Tosca
Tosca is a global leader in reusable plastic packaging and pooling solutions, serving grocery, fresh food, consumer goods, and other supply chain-intensive industries. Its automation-ready reusable crates, pallets, and bins are designed for durability, hygiene, and long service life within shared pooling networks.
More information: www.toscaltd.com
Rick LeBlanc, EMBA, is the founder and editor of Reusable Packaging News (subscribe to the free newsletter) and editor of Western Pallet Magazine. A supply chain journalist with more than 30 years of experience, he specializes in pallets, reusable packaging, material handling and related operations. Rick is co-author of Pallets: A North American Perspective and Pallets & Progress: A Collected History of Pallets and Palletized Handling 1922–1945. He is also an advisory board member of the Virginia Tech Center for Packaging and Unit Load Design. Read Rick’s full bio.
