Iperal has increased its operational capacity with the opening of a new Fresh Food Centre in Giussano, a 50,000 m² facility designed to manage fresh products and the retailer's "Fatto da Noi" range. The site incorporates automated systems and is powered by 4,300 solar panels. The new hub prompted a review of the packaging used to move fruit and vegetables from suppliers to stores, as the existing mix of cardboard, plastic, and wooden crates generated waste, created pallet-handling issues, and resulted in inconsistent store displays.
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The retailer adopted reusable plastic crates and bins supplied by Tosca to support a standardised and automation-compatible system. The crates are designed for repeated use within a pooling model in which assets are collected, cleaned, and redistributed. Their consistent dimensions allow for uniform stacking and presentation, and the plastic construction provides durability during handling and transport. Iperal now uses 60x40 and 30x40 crates in various heights, along with larger bins that circulate between suppliers, the new centre, and stores.
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According to Tosca, the introduction of standardised reusable crates has simplified logistics and aligned with Iperal's shift away from single-use packaging. The uniform structure of the crates has improved pallet stability, supporting safer handling and enabling smoother movement through automated lines. Waste-management requirements have also been reduced due to the lower volume of disposable materials.
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Iperal reports that the crates have integrated into automated systems without major adjustments. "Tosca's automation-ready RPCs fit seamlessly into our existing lines, ensuring smooth handling, consistent stacking, and reliable flow through every stage of the automated process," said Lorenzo Zecca, Supply Chain Director at Iperal. He stated that the system has delivered faster throughput and fewer stops, supporting more consistent processing from warehouse to store.
In retail outlets, fresh products are now displayed in a more uniform manner due to the standard crate format. The robust design has provided added protection during transport, contributing to fewer losses and more consistent supply quality.
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The switch to reusable packaging forms part of Iperal's broader sustainability trajectory by reducing waste volumes and limiting the environmental impact associated with single-use materials. Quantified savings are still being assessed, but reductions in waste streams and improvements in operational flow are already evident.
The retailer is expanding the use of reusable assets to additional suppliers in countries including Spain and the Netherlands. Further adjustments to in-store replenishment processes are being considered to improve efficiency and ergonomics. The collaboration between Iperal and Tosca is described by the retailer as ongoing, with the reusable-crate system forming part of its long-term supply-chain development.
© ToscaFor more information:
Hannah Hambleton
Tosca
Email: [email protected]
www.toscaltd.com
