How R. Brush Farms found a better way to protect their broccoli

In Blenheim, Ontario, R. Brush Farms puts quality and sustainability at the forefront of their business.  

Known for premium single-head broccoli, this fourth-generation family farm partnered with Tosca to tackle persistent packaging issues while investing in holistic sustainability initiatives. 

“We’ve found that many sustainability investments also create a positive impact on our bottom line over time. In 2024, we installed solar panels, reducing energy consumption and spending by 80%. The windmills we added in 2007 are four 20 mega watt wind turbines that go directly back into the local power grid.“

When it came to our transport packaging, we’ve also enjoyed the dual benefit of sustainability impact and savings. 

The packaging problem: Traditional boxes aren’t up to the task

For years, R. Brush Farms tried to solve a common problem throughout the produce industry: traditional cardboard boxes that literally can’t stand up to the demands of transporting goods. 

When cardboard boxes fall apart during transport, quality of the farm’s product can become compromised, leading to rejections and food waste. With every head of broccoli representing months of careful work, packaging failures were a weak line in an otherwise strong operation.

It was time to find a solution to protect R. Brush Farm’s bottom line and reputation.

Packaging challenges in the produce industry 

The traditional packaging solution in the food industry has long been corrugated cardboard boxes, which were cost-effective and widely available. 

However, as the supply chain has geographically expanded to serve broader markets, and with broader use of automation, this solution has not kept pace with product demands. 

Demands are especially high for the produce industry. Packaging must preserve freshness over longer distances while protecting items from damage. Each type of produce has specific needs—some require ventilation to manage respiration rates, while others need sturdier materials to prevent crushing. 

At the same time, growers and retailers face mounting pressure to reduce single use materials, minimize waste, and meet sustainability goals.

Adding to the complexity, regulations like the Food Safety Modernization Act now require traceability throughout the supply chain, placing additional demands on packaging solutions.

Enter Tosca: Finding reliability in a high-demand industry

“At first, we tried two other RPC providers, and getting clean containers to pack in was an uphill battle,” Regan recalls. 

When Loblaw, Canada’s largest retailer, introduced R. Brush Farms to Tosca’s reusable plastic containers (RPCs), the difference was immediate. 

One standout improvement was in sanitation. 

Tosca’s wash process is ISO 22000 certified, the industry’s most stringent food safety management standard. Learn more about how Tosca handles washing and food safety safeguards. 

Packing in Tosca’s containers has also improved the packing and shipping process. 

Tosca’s standardized designs make it easy to stack and secure the containers. This means less time spent adjusting loads or addressing shifting during transit. With Tosca’s RPCs, R. Brush Farms can focus on quality control and logistics instead of constantly troubleshooting faulty packaging.

Tosca’s customer service also impressed the farm. Regan notes that any issue is resolved quickly, and the ability to connect with customer support has made all the difference. 

How R. Brush Farms uses Tosca products 

R. Brush Farms uses Tosca’s RPCs—the 6423, 6425, and 6428 models—designed to handle the challenges of transporting fresh produce. These solutions offer benefits such as:

The difference Tosca makes: Efficiency meets sustainability

R. Brush Farms’ switch to Tosca products improved their packaging process and reduced waste. By swapping cardboard boxes with Tosca’s reusable containers, they solved long-standing issues with durability and established a more reliable system for transporting their product.

The farm appreciates Tosca’s responsiveness, noting that issues are resolved quickly, even outside regular business hours.

A sustainable solution for growers for today and tomorrow

Whether you’re looking to protect your products during transport, reduce packaging waste, or improve your overall efficiency, Tosca has solutions to meet your needs.

Here’s how you can get started:

• Learn more: Explore Tosca’s reusable plastic containers and discover the benefits for your supply chain.
• Start small: Interested in testing before you commit? Tosca offers pilot programs to help you evaluate the impact of reusable packaging on your business.
• Get support: Tosca’s team is ready to assist with onboarding, troubleshooting, and optimizing your packaging process for long-term success.