As supply chains become more automated, regulated and cost-conscious, reusable packaging is evolving from a procurement decision into a strategic infrastructure asset, according to reusable packaging specialist Tosca.
The company argues that businesses are increasingly evaluating packaging based on its contribution to operational performance rather than purchase price alone. Instead of comparing the upfront cost of load carriers, companies are adopting a total cost of ownership (TCO) approach that considers factors such as handling efficiency, product protection, transport performance, hygiene, compliance and sustainability over the packaging’s entire lifecycle.
According to Tosca, this shift is driving greater interest in reusable pooling systems, which provide access to pallets, crates and containers through shared networks rather than requiring companies to own and manage large packaging fleets.
“Companies are no longer solely looking on purchase price. They are looking at the total value that packaging delivers across their operations. When you factor in handling, product protection, operational efficiency and long-term costs, load carriers are no longer just a means of transporting goods. They have become critical infrastructure for efficient, reliable supply chains,” said Vincent Nagels, Managing Director of Upstream at Tosca.
The company says standardised reusable assets can help improve operational consistency, particularly in increasingly automated warehouses and distribution centres, where variations in packaging dimensions or condition can lead to equipment stoppages and inefficiencies. It also highlights benefits for retail operations, including faster shelf replenishment, reduced waste and more efficient storage through collapsible reusable crates.
Tosca also points to the flexibility provided by pooling networks, which allow businesses to access packaging assets as needed rather than investing in additional inventory during seasonal peaks or periods of supply chain disruption.
“The real value of pooling goes far beyond providing reusable load carriers. By balancing demand across industries and locations, pooling providers help customers absorb seasonal peaks and supply chain fluctuations, ensuring load carriers are available where and when they are needed most,” Nagels added.
The company believes regulatory developments, including the EU’s Packaging and Packaging Waste Regulation (PPWR) and Extended Producer Responsibility (EPR) schemes, are further accelerating the transition towards reusable systems by encouraging greater reuse, circularity and improved control over packaging flows.
Looking ahead, Tosca expects digitalisation and automation to play an increasingly important role in reusable packaging networks, with technologies such as AI supporting asset inspection, sorting and repair while improving the management of high-volume packaging fleets.
“As supply chains become more connected and performance expectations continue to rise, reusable pooling systems are likely to become increasingly embedded within the networks they serve. The conversation will move beyond packaging itself towards how businesses build the physical infrastructure needed to support efficient, resilient and scalable supply chains,” said Marco Gonzalez, Managing Director – Central Europe at Tosca.
