Iperal has introduced a fully standardised reusable packaging system across its fresh supply chain, selecting automation-ready reusable plastic crates (RPCs) from Tosca as part of a major operational redesign linked to the opening of its new Fresh Food Centre in Giussano.
The Northern Italian supermarket chain, which operates 56 stores and has expanded its fresh portfolio in recent years, inaugurated the 50,000 m² facility in 2025. The site serves as the central hub for fresh produce and the company’s “Fatto da Noi” range, incorporating automated handling systems and on-site solar generation.
The commissioning of the centre prompted a reassessment of long-standing logistical practices. Iperal had previously relied on a mix of cardboard, plastic and wooden crates for produce distribution, a system that generated substantial waste streams, created pallet-handling inconsistencies, and resulted in variable presentation across stores. The move toward a more automated and sustainability-driven operation led the retailer to examine alternatives compatible with closed-loop logistics.
Iperal ultimately selected Tosca’s Wood Look RPCs and bins to standardise packaging across its fruit and vegetable supply chain. The reusable crates are designed for repeated use within Tosca’s pooling model, which manages collection, cleaning and redeployment. According to the company, the RPCs provide the aesthetic benefits of wooden displays while offering the durability, hygiene and product protection of plastic.
“Our partnership with Iperal is a great example of how reusable packaging can unlock both operational and environmental value,” said Gian Paolo Mezzanotte, Managing Director – Italy, France, Spain at Tosca. “By introducing a standardised, reusable system, we’ve helped simplify logistics, enhance product quality, and support Iperal’s long-term sustainability goals.”
Iperal now uses Tosca’s 60×40 and 30×40 RPCs in multiple heights, along with larger bins moving from suppliers to the Fresh Food Centre and then to stores. The retailer cites handling stability, uniformity and automation-readiness as core advantages. Standardised crate dimensions support smoother palletising and movement through the warehouse, which is essential in an automated environment.
The performance of the packaging within automated lines has been a central benefit, according to Lorenzo Zecca, Supply Chain Director at Iperal: “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. We’ve seen faster throughput, fewer stops on the line, and more consistent performance overall. The durability and uniformity of the RPCs have reduced disruptions, improving both efficiency and reliability across our operation and supply chains.”
Beyond logistics, Iperal reports improved in-store presentation, reduced product damage during transport, and a more coherent visual layout for fresh produce categories. The retailer notes that environmental benefits—lower waste volumes, reduced reliance on single-use materials and decreased CO₂ emissions—are emerging as the new system scales, though precise measurements are ongoing.
The collaboration is set to expand. Iperal is extending the use of Tosca crates to additional suppliers in Spain and the Netherlands and is evaluating new approaches to in-store replenishment to improve ergonomics and speed. The company characterises the relationship with Tosca as “constructive, productive, and efficient,” positioning reusable assets as a strategic component of its modernised supply chain.
