Automation-ready crates set a new standard for fresh supply chains

As demand for high-quality fresh products rises across Northern Italy, Iperal has taken a major step toward a more efficient and sustainable supply chain. The retailer’s new Fresh Food Centre in Giussano (MB) — a 50,000 m² facility launched in 2025 — has become the engine behind this shift, combining advanced automation, 4,300 solar panels, and a renewed approach to how fruit and vegetables move from suppliers to stores.

The opening of the centre prompted Iperal to address a longstanding logistical issue: the heavy dependence on cardboard, plastic and wooden crates. These single-use or mixed-material formats generated considerable waste, weakened pallet stability and created inconsistent displays across stores. With automation now central to Iperal’s operations, the retailer identified a clear opportunity to transition to a more durable, circular and standardised packaging solution that would support stable growth while aligning with its environmental commitments.

Reusable, automation-ready crates redefine Iperal’s logistics

Iperal chose Tosca’s Wood Look reusable plastic crates (RPCs) and bins to build a fully standardised system compatible with the retailer’s automated lines. These RPCs combine the visual warmth of wood — ideal for in-store presentation — with the hygiene, protection and repeat-use durability of plastic. Through Tosca’s pooling service, each crate is collected, washed and returned into circulation multiple times, replacing single-use packaging with a cost-efficient circular model.

The retailer now deploys Tosca’s 60×40 and 30×40 RPCs in various heights, along with larger bins that flow seamlessly from suppliers to the Fresh Food Centre and directly into stores. Their uniform dimensions improve stacking, movement and storage across the entire supply chain, contributing to a consistent presentation of fresh products on the shop floor.

Industry representatives highlighted that the partnership shows how reusable packaging can simultaneously deliver operational, environmental and in-store benefits. They noted that the move to a standardised, pooled solution has simplified logistics, improved produce protection and supported Iperal’s long-term sustainability roadmap.

Measurable gains in automation performance and sustainability

Since adopting Tosca’s reusable assets, Iperal has reported visibly improved pallet stability and safer handling — both essential for a high-throughput automated facility. The crates’ consistent build quality has reduced stoppages on the line, helped maintain steady material flow, and contributed to faster processing times.

Supply chain leaders at Iperal explained that the RPCs integrate smoothly into the existing automated infrastructure. According to internal assessments, the uniformity and durability of the crates have helped minimise disruptions and supported more reliable performance throughout the warehouse and distribution network.

The impact is equally visible in stores. Fresh products now arrive in cleaner, more uniform displays, strengthening the retailer’s emphasis on quality and customer satisfaction. The improved protection during transit has led to fewer damaged items and more consistent availability of high-grade produce.

Environmentally, the introduction of reusable crates is reducing packaging waste, lowering emissions linked to disposal, and supporting a broader shift toward circular resource management. While full year-on-year environmental savings are still being quantified, the operational improvements and waste reductions are already evident across daily workflows.

A partnership expanding across regions and suppliers

Encouraged by the results, Iperal is extending Tosca’s reusable solutions to additional suppliers in Italy as well as partners in Spain and the Netherlands. The company is also evaluating further in-store optimisation opportunities to improve ergonomics and replenishment speed. Iperal describes the collaboration as highly productive and views Tosca as a strategic ally in building a greener, more efficient supply chain for the years ahead.

About Tosca

Tosca is a global leader in reusable plastic packaging and performance-driven pooling solutions. The company provides smart, durable and sustainable assets for growers, suppliers, and retailers, enabling stronger circularity and improved supply chain performance across multiple sectors.

Looking to modernise your fresh supply chain? Let’s connect and explore how reusable, automation-ready solutions can elevate your operations.