How Converting to Tosca Reusables Works

Switching to reusables doesn’t have to be disruptive. Tosca’s milestone-based roadmap makes it straightforward, while delivering value at every stage. Here’s how our team guides you from the first test to a full rollout.

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Why Make the Switch?

Corrugated is bad for the environment and it’s slowing down your operations. When you switch to reusables, you’ll experience transformative impact across your supply chain that goes beyond sustainability.

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Labor savings

Significant in-store stocking efficiency, zero time at the baler, retail-ready solutions.

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Larger loads

Reusable pallets are lighter than wood, letting you cube out before you weigh out.

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Emissions reduction

Achieve reduced CO2 emissions when switching from other packaging solutions.

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Reduced shrink

Ensure freshness through proper ventilation and protect product quality from box crush.

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More bins per haul

Reusable bulk bins can be folded to take up less space than rigid IBCs, leading to fuller trucks and fewer trips.

Explore Reusables Benefits
Heavy impact. Light lift.

Our Four-Step Process

With 60 years of experience guiding supply chain leaders to reusable solutions, we’ve mastered the process. Our goal is to minimize your workload by handling most of the conversion process.

Discovery & Business Case
Discovery & Business Case
Retailer & Supplier Readiness
Retailer & Supplier Readiness
Pilot Program
Pilot Program
Full Rollout & Ongoing Optimization
Full Rollout & Ongoing Optimization
  • Evaluate product mix & network
  • Build a business case
  • Tailor our process to your needs
  • Define KPIs
  • Key deliverable: A quantified business case with projected savings and sustainability impact
  • Conduct on-site visit
  • Align retailer and supplier stakeholders
  • Prepare with training and onboarding resources
  • Run small-scale operational test
  • Key deliverables: Pre-pilot findings, training materials, retail signage, SOPs, and supplier onboarding kit
  • Execute a tailored, 30-to-60-day pilot
  • Capture quantitative data and participant feedback
  • Validate operational fit
  • Key deliverables: Custom pilot plan, success metrics dashboard, post-pilot performance report
Learn more about piloting
  • Manage structured rollout
  • Review performance with in-person QBRs
  • Continue training and optimization
  • Key deliverables: Rollout schedule and confirmation checklist, on-site support plan, sustainability impact reports, quarterly business reviews (QBRs)

FAQs about Converting to Reusables

A grower removes bundles of fresh US green onions from a soiled corrugated cardboard box and places them into breathable, reusable produce crates, while a spectator records inventory and product quality on a paper notepad.

Will this disrupt my operations?

No. Tosca mirrors your current handling processes and designs reverse logistics to avoid bottlenecks.

How does Tosca handle training?

We provide on-site sessions, videos, posters, and quick-start guides for both suppliers and retailers.

What if my supply chain partners aren’t aligned?

Tosca works with every stakeholder, including suppliers, retailers, and 3PLs, to ensure smooth adoption.

Is the pilot program risky?

Pilots are low-risk and high-signal. They let you validate benefits before committing. You can read more about our pilot program here.

How long does a pilot typically last?

Pilots are designed to be short and efficient, giving you insights quickly. Our average pilot lasts 30-to-60 days.

What happens after the pilot?

We analyze results and participant feedback and share a post-pilot report. If all parties agree the pilot was a success, we plan a rollout, taking account of seasonality and other factors, and scale for full conversion.

How does Tosca ensure surety of supply?

We maintain one of the highest OTIF rates in the industry and forecast our pool to meet your needs.

What kind of support does Tosca provide during rollout?

We plan your post-pilot rollout completely, including scaling training to the rest of your supply chain, troubleshooting any challenges and providing ongoing suggestions for improvements.

Ready to get started?

Start with a savings and sustainability analysis or set up a pilot.