How the “careful consumer” is changing food retail: Trends to watch in 2025
Maybe it’s the higher costs at checkout or a news report on the potential impact of looming tariffs on avocados....
Protecting eggs in a high-risk supply chain: How Versova upgraded its packaging
by hemasanghavi, under Customer stories
In this article
As one of the nation’s premier egg producers, Versova supplies millions of eggs nationwide.
However, getting those eggs safely from farm to table requires a strict protocol around food safety.
Like many other businesses, Versova initially saw packaging as a logistics issue that could reduce breakage along the supply chain.
“The main driver for switching to Tosca RPCs was the reduction in broken eggs during transportation. These reusable plastic crates allow some additional protection for the egg cartons which resulted in an average 66% reduction in egg loss.”
The risk factors in egg transportation
Even with strict protocols, maintaining sanitation beyond the farm is challenging. Each step in the supply chain, from processing plants to distribution centers to retail cold storage, introduces a contamination risk for eggs.
These risks are amplified with corrugated:
- No ventilation prevents eggs from cooling down quickly and maintaining the correct temperature, allowing bacteria like salmonella to grow inside the eggs.
- Lack of stability can cause boxes to collapse and loads to shift, leading to breakage and increased shrink.
- Porous corrugated traps moisture, bacteria, and other contaminates and transmits them on a surface that is essentially uncleanable.
Creating a controlled, food-safe packaging system with Tosca
To eliminate packaging-related contamination risks, Versova transitioned to Tosca’s reusable plastic crates (RPCs)—a sanitized, traceable, and structurally stronger alternative to corrugated boxes.
“We were introduced to Tosca’s reusable plastic crates to replace our use of cardboard boxes for specific orders. RPCs are a good solution to us as they are a functional replacement but also come washed and sanitized, reducing our concern.”
Why Versova chose Tosca’s crates
Versova relies on Tosca’s RPCs to protect eggs during transportation, meet food safety regulations, and improve supply chain efficiency. Key features include:
| SANITATION | Tosca’s RPCs undergo an ISO 22000-certified wash process that removes all organic material and contaminants. |
| VENTILATION | Tosca’s RPCs are well-ventilated, allowing eggs to cool five times faster than corrugated. |
| DURABILITY | Engineered to withstand refrigeration, high humidity, and washdowns without degrading. |
| EFFICIENCY | Designed for modern automated processes, Tosca’s RPCs are uniform in size and structure. |
| TRACEABLE | Tosca’s RPCs can be tracked throughout the supply chain. |
Impact of right packaging
By eliminating single-use packaging, Versova removed a contamination risk and improved supply chain efficiency. The key benefits include:
- Reduced product loss: Tosca’s RPCs are designed to maintain structural integrity throughout the supply chain. This means less breakage, labor costs, and food waste.
- Increased food safety: Single-use corrugated boxes introduced unknown contamination risks. Tosca’s RPCs are sanitized and standardized, ensuring that packaging never becomes a food safety liability.
- Lower operational costs: RPCs are moisture-resistant and durable, eliminating the need for constant repurchasing of single-use packaging while reducing labor costs tied to handling compromised shipments.
- Increased freshness: In the right secondary packaging, eggs maintain freshness thanks to consistent cooling. This decreases shrink and improves consumer safety.
- Compliance: Tosca’s traceable, reusable packaging reduces barriers to compliance with emerging regulations, which allows Versova to document its food safety measures across the entire supply chain.
Partner with Tosca
Tosca has been a leader in reusable packaging solutions for over 60 years, helping businesses like Versova strengthen food safety and biosecurity in their supply chains. Here’s how to get started:
- Learn more: Discover Tosca’s reusable packaging options when you talk to a Tosca egg expert.
- 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.
Take the next step in securing your supply chain. Contact Tosca today.
Published on August 11, 2025
Updated on August 11, 2025
About the author
Related resources
Retail