Tosca says pooling is turning reusable packaging into supply chain infrastructure

Reusable packaging is increasingly being treated as part of supply chain infrastructure rather than a basic purchasing expense, packaging pooling company Tosca said.

Higher operating costs, greater use of automation and stricter packaging rules are encouraging businesses to look beyond the purchase price of pallets, crates and other load carriers. Companies are instead considering their total cost over the full lifecycle, including handling, transport, storage, hygiene, product protection and waste management.

Under a pooling model, businesses use reusable packaging supplied, collected, inspected and redistributed through a shared network. This reduces the need for individual companies to buy, store and manage their own large packaging inventories.

Vincent Nagels, Tosca’s Managing Director of Upstream, said companies were increasingly assessing the overall value packaging brings to their operations. He noted that handling efficiency, product protection and long-term operating costs can make load carriers an important part of a reliable supply chain.

Standard packaging supports automation

According to Tosca, standardisation is one of the main operational benefits of pooling. Crates and pallets with consistent dimensions, specifications and quality are easier to handle manually and through automated systems.

This is particularly important as warehouses, distribution centres and packing operations introduce more automated unloading, storage, picking and packing processes. Differences in packaging size, weight or condition can cause jams, interruptions and equipment downtime.

Reusable plastic crates can also support fresh produce operations because they maintain their shape in humid areas and environments with changing temperatures. This can help protect products during transport and handling while supporting hygiene and food safety procedures.

In retail stores, collapsible crates take up less space when empty and can reduce the time employees spend sorting and disposing of single-use packaging. They may also make shelf replenishment and backroom storage more efficient.

Pooling networks help manage seasonal demand

The pooling network also allows companies to increase or reduce the number of load carriers they use according to demand.

This can be useful for growers, suppliers and retailers managing seasonal production peaks or unexpected changes in supply volumes. Instead of purchasing additional crates or pallets that may only be needed for a limited period, companies can obtain them through the wider pool.

Nagels said pooling providers can balance demand between industries and locations, helping customers access packaging where and when it is required.

Reuse supports new packaging requirements

Tosca also linked the expansion of pooling to regulatory changes, including the EU Packaging and Packaging Waste Regulation and extended producer responsibility requirements.

These rules are increasing pressure on businesses to reduce packaging waste, improve recyclability and introduce more reusable systems. Pooling keeps crates and pallets in circulation through repeated use, collection, inspection and repair, offering companies a way to incorporate reuse into normal supply chain operations.

Marco Gonzalez, Tosca’s Managing Director for Central Europe, said reusable pooling systems were likely to become more closely integrated with logistics and retail networks as supply chains become more connected.

According to Gonzalez, future developments will include wider use of digital asset management and artificial intelligence for activities such as sorting, inspection and repair. These technologies could help operators track packaging more accurately, reduce unnecessary transport and manage large reusable packaging pools more efficiently.

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