Fiordelisi, an Italian producer of sun-dried and semi-dried vegetables based in Apulia, has optimised its logistics processes by implementing reusable foldable plastic Active Lock crates supplied by Tosca. Replacing traditional stackable plastic crates with a pooling system based on foldable containers has increased storage capacity, enabled more product to be transported per truck and reduced transport-related emissions. This solution is aligned with Fiordelisi's long-term strategy focused on reducing environmental impact while maintaining high quality and cost-efficient operations.
Fiordelisi manages its entire value chain, from cultivation through processing, supplying retail chains and manufacturers across Italy and Europe. Due to high seasonal volumes, particularly in the sun-dried tomatoes segment, the efficiency of inter-site flows and transport of finished goods is critical for operating costs and environmental footprint. The company systematically analyses its processes, seeking solutions that reduce resource use and emissions while maintaining stable quality of supply.
From traditional crates to reusable solutions
Until recently Fiordelisi used conventional stackable plastic crates for transporting semi-finished products between plants and for outbound shipments. However, such packaging occupied significant space once emptied, which limited logistics efficiency both in warehouses and in the return transport of empty packaging. The limited number of crates that could be loaded onto a single vehicle translated directly into the number of trips, transport costs and associated emissions.
In the search for a more efficient and sustainable alternative, the company began to analyse reusable solutions that could improve both empty-crate logistics and finished-goods transport. In this context, the reusable plastic crate system offered by Tosca was identified as an opportunity to optimise space utilisation, reduce packaging waste volumes and support Fiordelisi's sustainability objectives.
Foldable Active Lock crates tailored to real operating conditions
To address these challenges, Tosca proposed foldable plastic Active Lock crates designed for repeated use. The construction of these containers has been developed to provide high durability and resistance to intensive use in demanding food processing environments. Once emptied, the crates can be folded flat, significantly reducing the space required for storage and for transport of empty packaging between Fiordelisi locations.
At the same time, the rigid structure and secure Active Lock system ensure load stability during transport, limiting the risk of product damage and quantitative losses. Combined with Tosca's pooling model, in which the same packaging units are used repeatedly in circulation, the solution supports a circular approach to plastic packaging usage.
Multiple reuse of crates reduces the need for single-use packaging, decreases waste volumes and helps Fiordelisi prepare for evolving regulatory and environmental requirements, including the planned PPWR rules. As highlighted by Marco Mangano, Sales Manager – Retail at Tosca: "Our reusable packaging and pooling model is designed to reduce waste, cut emissions and improve performance in real-world operations. Fiordelisi is a strong example of how these benefits come together in practice."
Measurable effects in efficiency, costs and environment
After switching to Active Lock crates, Fiordelisi has recorded concrete operational improvements. The foldable design allows the company to store five times more empty crates in the same warehouse space, clearly improving storage capacity utilisation and reducing the need for internal handling of packaging.
Transport efficiency has also increased substantially. Compared with the previous packaging solution, Fiordelisi can now load an additional 560 filled crates per truck. In practice this equates to more than one extra tonne of sun-dried tomatoes per shipment, which improves transport cost efficiency and reduces the number of required trips.
As explained by Antonio Fiordelisi, General Manager at Fiordelisi: "Being able to send over a tonne more product on the same truck makes our transport both more efficient and more sustainable. We reduce the number of trips and the emissions linked to them."
Gianpaolo Mezzanotte, Managing Director Southern Europe at Tosca, also points to the measurable benefits: "When you can transport more product in the same space, you spend less, generate less waste and emit less CO2. These are tangible, measurable benefits that reusable packaging delivers."
Long-term partnership and continuous improvement
Looking ahead, Fiordelisi plans to keep operational efficiency and sustainability as priorities, treating Tosca as a long-term partner in this area. The company notes that Tosca provides efficient, consistent and reliable packaging solutions with high quality and a favourable cost-to-performance ratio.
Gianpaolo Mezzanotte emphasises the customer's engagement: "Fiordelisi is proactive in improving both supply chain performance and sustainability. Tosca is proud to support them with reusable solutions that help deliver operational, economic and environmental value."
The cooperation between Fiordelisi and Tosca illustrates how well-designed reusable plastic packaging can deliver measurable improvements in transport efficiency, cost control and achievement of environmental objectives in food supply chains.
