How reusable packaging is improving logistics efficiency in food processing

Italian producer Fiordelisi has upgraded its logistics by switching to reusable packaging from Tosca, improving both efficiency and sustainability. The change has freed up storage space, increased truck loads, and helped cut transport-related emissions.

Fiordelisi is based in Puglia and controls its production from the field to the finished product, supplying retailers and manufacturers across Italy and Europe. As sustainability is already part of how the company operates, improving logistics became an obvious next step.

Rethinking storage and transport between sites

For years, Fiordelisi relied on conventional plastic crates for internal transport and outbound deliveries. They were reliable enough, but when empty they took up far more space than ideal. At busy times of the year, especially during the sun-dried tomato season, this translated into underfilled trucks, higher costs, and avoidable inefficiencies.

To address this, Fiordelisi began looking for a reusable solution that could improve space management without compromising product safety. Tosca’s reusable plastic crates stood out as a practical alternative that aligned with the company’s sustainability goals.

Foldable crates designed for everyday use

The solution introduced was Tosca’s Active Lock folding crates. Built for repeated use in demanding food processing environments, the crates combine a rigid structure with a secure locking system to protect products during transport. When empty, they fold flat, dramatically reducing the space required for storage and reverse logistics.

The solution fits well with Fiordelisi’s multi-site operations, where empty crates must be moved and stored in large volumes. Reuse also reduces dependence on single-use packaging and supports compliance with evolving EU rules, including the PPWR.

Marco Mangano, Sales Manager – Retail at Tosca, said that the company’s pooling model is designed to deliver practical results by helping customers reduce waste, cut emissions, and improve performance without adding unnecessary complexity.

Clear, measurable results

Since adopting the Active Lock Crates, Fiordelisi has seen tangible improvements. The foldable design allows the company to store up to five times more empty crates in the same warehouse space, easing internal logistics and reducing handling time.

Transport efficiency has also improved. Each truck can now carry 560 more filled crates than before, which translates into over one additional tonne of sun-dried tomatoes per shipment. This higher load factor means fewer journeys are needed, lowering fuel consumption and emissions while improving cost efficiency.

Antonio Fiordelisi, General Manager at Fiordelisi, explained that being able to transport more than a tonne of additional product on the same truck has made logistics both more efficient and more sustainable, thanks to fewer trips and lower emissions.

Gianpaolo Mezzanotte, Managing Director Southern Europe at Tosca, added that optimising space leads to immediate benefits, including fewer journeys, lower emissions, reduced waste, and stronger overall operational performance.

A long-term approach to sustainability

Fiordelisi sees this project as part of a broader, ongoing effort to improve its supply chain. The company views Tosca as a long-term partner, providing reliable, high-quality solutions that support both efficiency and sustainability.

Fiordelisi noted that the quality of the solutions, their efficiency, and the balance between cost and value have made a clear difference in day-to-day operations.

By working together, Fiordelisi and Tosca are showing how reusable packaging can deliver measurable gains across storage, transport, and sustainability, offering a practical example of how food supply chains can reduce their environmental footprint while improving performance.

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