Iperal Transforms Fresh Supply Chain With Tosca’s Automation-Ready Reusable Plastic Crates
Iperal, one of Northern Italy’s most dynamic supermarket chains, has built its reputation on quality, service and a close connection to the communities it serves. With 56 stores, more than 50,000 employees and an expanding fresh offering, the retailer’s operations have grown significantly since its founding in 1986. This growth reached a new milestone in 2025 with the opening of the Fresh Food Centre in Giussano (MB), a 50,000 m facility designed to manage fresh products and Iperal’s own “Fatto da Noi” (Made by Us) range. Equipped with fully automated systems and powered by 4,300 solar panels, the new hub sets new standards of efficiency, quality and sustainability.
The launch of the new centre prompted Iperal to rethink a long-standing logistical challenge: the reliance on cardboard, plastic and wooden crates to move fruit and vegetables from suppliers to stores. These single-use and mixed-material solutions generated large volumes of waste, contributed to unstable pallet handling, and led to inconsistent in-store presentation across locations. With the opening of the Fresh Food Centre, Iperal saw a clear opportunity to move away from single-use materials and invest in a more efficient, sustainable solution compatible with automation that would support both the company’s growth and its environmental commitments.
Tosca’s reusable, automation-ready plastic crates deliver transformation
Iperal selected Tosca’s Wood Look reusable plastic crates (RPCs) and bins to create a streamlined, sustainable and automation-ready packaging system. Designed for resilience and repeat use, the RPCs combine the aesthetic appeal of a traditional wooden display with the durability, hygiene and product protection of plastic. This wood-look finish helps create clean, attractive and well-organised shelves that elevate the shopper experience and support increased sales. Through Tosca’s pooling model, each crate is collected, cleaned and redeployed multiple times, eliminating the waste associated with single-use packaging and providing a cost-efficient circular solution.
Today, Iperal uses Tosca’s 60×40 and 30×40 RPCs in multiple heights as well as larger bins that move seamlessly from suppliers to the Fresh Food Centre and onward to stores. Their standardised footprint and consistent build quality enable smooth handling, efficient stacking, and uniform presentation of fresh products once in store – an important element of Iperal’s customer experience.
“Our partnership with Iperal is a great example of how reusable packaging can unlock both operational and environmental value,” says 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.”
A visible leap in efficiency, sustainability, and automation performance
Since making the transition, Iperal has observed clear benefits. Pallet stability has increased, making handling safer and more predictable – an essential advantage for an automated facility. The consistent crate dimensions streamline stacking and movement through the warehouse, helping reduce downtime and supporting a smooth material flow. The simplification of waste management has also been significant, with less reliance on single-use materials and fewer disposal processes required.
Tosca’s solutions have integrated into Iperal’s automated systems with ease and delivered measurable improvements in operational efficiency: “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,” explains Lorenzo Zecca – Supply Chain Director at Iperal. 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.”
In stores, shoppers now encounter fresh products presented in a cleaner, more uniform way, reinforcing Iperal’s commitment to quality. The crates’ durability protects produce more effectively during transport, contributing to a reduction in damage and a more reliable supply of high-quality goods.
Environmentally, the shift to reusable packaging supports Iperal’s broader sustainability commitments – reducing packaging waste, lowering CO emissions, and promoting more responsible use of resources. While precise savings are still being measured, the benefits are visible every day in smoother operations, reduced waste, and an enhanced shopping experience for customers.
A growing partnership shaping the future of Iperal’s supply chain
The success of the collaboration has inspired Iperal to expand the use of Tosca’s reusable assets to additional suppliers, including partners in Spain and the Netherlands. The retailer is also exploring ways to enhance its in-store replenishment operations to improve ergonomics and efficiency further. Describing the collaboration as “constructive, productive, and efficient”, Iperal views Tosca as a strategic partner in building a smarter, greener supply chain fit for the future.
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