Innovative Plastic Container Offers Advantages over Cardboard.


On February 11th Tosca, an Atlanta-based manufacturer of reusable packaging and supply chain applications for perishables, announced today the results of a time and motion study for eggs. Advantage Consulting, a third-party industrial engineering firm, was commissioned by Tosca to conduct the study to evaluate the impact of outer packaging on store labor. The study compared the time required to stock and manage egg displays in a grocery store using traditional one-way corrugated shipping boxes compared to the Tosca's Reusable Plastic Container (RPC). The study was conducted in regional grocery stores in the Midwest during 2018. Over two separate one-week periods an engineer traveled to selected representative stores and recorded the time required to stock and rotate eggs in a display cooler. The first week considered traditional corrugated shipping boxes and the second week reusable plastic containers (RPCs) were used.

The comparison analyzed the multi-step process in the egg section of the dairy department comprising pulling egg cases from the cooler, stocking and rotating cartons, disposing of packaging and removing damaged eggs.

Findings from the study were:-

  • It takes less than half the time to stock an egg display using retail-ready RPCs compared to corrugated cartons. On average, in an 8-foot display case, RPCs stock and rotate product in 10 minutes versus 21 minutes for corrugated packaging.
  • Taking advantage of timesaving RPCs, retailers could achieve a 53 percent reduction in labor to manage the egg category.
  • Using RPCs, each store will save 56 hours of labor annually that can be reallocated to other tasks.

The study found that when using corrugated cartons, transfer to the display case significantly impacts stocking time by 35 percent. Rotation of product may also increase in stocking time by 24 percent.

With Tosca's retail-ready solution, eggs can be displayed directly in a custom designed RPC, eliminating the time-consuming tasks of removing, stacking, and rotating egg cartons. Tosca's unique one-step SmartWall TM design simplifies restocking and saves labor by allowing employees to place the container directly in the case and drop the front wall for display in one easy motion.

"We know that retailers are looking for a better way to identify cost and labor savings, improve supply chain efficiency and protect the product quality of perishables," said Eric Frank, president and CEO of Tosca. "This study helps validate that there is a better way to move eggs safely and efficiently from source to shelf. RPCs not only are easier and faster to stock but also help reduce shrink by offering the best protection available for fragile eggs."

Tosca ( is a leading provider of reusable packaging and supply chain solutions across a diverse range of markets including eggs, case-ready meat, poultry, produce, and cheese. The proven RPC system is a more efficient way to move fresh product safely from plant to shelf, substantially reducing breakage and labor cost, maintaining product quality, and optimizing overall supply chain efficiency for packers and retailers.

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