BIG Interview: Gianpaolo Mezzanotte on the hidden costs of weak pallet logistics 

Every extra kilo, unstable load, or damaged pallet eventually creates problems somewhere else in the fresh produce business, from higher costs to product losses and slower handling. 

That pressure is growing as logistics operations are expected to move faster while staying reliable and efficient. For companies transporting fruit and vegetables, even pallet design now has a direct impact. 

Tosca says those challenges were a key reason behind the development of a new pallet solution for the fruit and vegetable sector, with the company focusing on stability, easier handling, and long-term performance. 

Fructidor spoke with Gianpaolo Mezzanotte, Managing Director for Italy, France and Spain at Tosca, about the thinking behind the new pallet and why the company believes logistics equipment will increasingly need to deliver durability and efficiency without adding operational complexity. 

Fructidor: Can you tell us more about this new pallet and what makes it different? 

Gianpaolo Mezzanotte: We are very excited to introduce this new equipment into our portfolio. It is a 1200x800 plastic pallet with the exact same size and dimensions as a standard sized wooden pallet. It is a very strong product for several reasons.

The pallet is made entirely from recycled materials, including both post-consumer and post-industrial content. We are not using virgin material, so sustainability is a key concept behind the product. We also carried out extensive life cycle assessment studies and were able to demonstrate that this pallet performs better than a standard wooden pallet in terms of environmental impact and overall results. 

What operational advantages does the pallet offer for the fresh produce supply chain? 

GM: The pallet performs very well operationally. It is a multi-purpose pallet that was designed specifically with RPCs in mind, meaning our plastic crates. We created a special design on the top deck to ensure good anchorage between the RPC and the pallet so the unit load remains stable.

Normally, when you have plastic on plastic, there can be slippage, but with this design we are able to maintain a very stable unit load. This improves productivity across the supply chain, whether at distribution centres, warehouses, retailers, packing stations, growers, or logistics partners. 

The pallet is also designed with safety in mind. We introduced special elements underneath the top deck to improve friction with forklift forks and avoid slipping during handling operations. 

You also mentioned handling and ergonomics. Why was that important? 

GM: The pallet weighs only 21 kilos instead of the standard 25 kilos for a normal wooden pallet. In terms of manual handling, this is a major improvement. We also introduced handles on the top deck so operators can safely lift, move, and handle the pallet more easily while reducing strain and avoiding musculoskeletal problems. Safety is one of the most important priorities for us. 

How durable is the pallet compared to traditional wooden pallets? 

GM: The pallet is very strong because we introduced metal bars into the top deck. It is also guaranteed for 1,000 kilos in rack systems, which is a very strong performance. This is important because the pallet is not intended only for fruit and vegetables. It can also be used in beverage, grocery, FMCG, and other sectors. 

Another important advantage is that plastic avoids the split-outs and damage typically associated with wooden pallets. The pallet is also washable with integrated drainage holes, reducing contamination risk. We introduced a slightly corrugated surface on the top deck to prevent cartons from slipping. 

Repairability also seems to be an important part of the concept, right? 

GM: Yes, the pallet consists of four parts: one top deck and three skids. The skids are removable, so if one part is damaged, we can replace only that component instead of scrapping the entire pallet. We believe this is a major innovation and a big step forward. 

What are Tosca’s plans for deploying the pallet? 

GM: Initially, we will use the pallet in the fruit and vegetable supply chain together with RPCs. After that, we plan to progressively expand its use into other sectors, including private label operations and fast-moving consumer goods. The goal is to progressively deploy the pallet more broadly across the supply chain. 

The pallet also includes RFID technology. How does that work? 

GM: The pallet guarantees full traceability because we integrated RFID technology directly into it.  We use integrated RFID tags on each pallet, allowing us to connect it to monitoring systems throughout the supply chain. This is another important advantage and feature we added to the pallet. 

Companies looking to improve pallet stability, handling safety and long-term logistics performance can send their inquiry for a free consultaiton.