Tosca presents recycled plastic pallet for produce logistics

Tosca showcased its euro-size Circular Pallet CP1208 at Fruit Attraction. Developed in partnership with Cabka, the reusable and recyclable transport pallet is intended to support safer, more efficient and sustainable fresh produce supply chains, while helping operators prepare for changing regulatory requirements. The load carrier is made from 100% recycled plastic and has been designed for repair, repeated use and recycling at the end of its service life. According to Tosca, the pallet also addresses the operational requirements of growers, producers, manufacturers and retailers, including compatibility with automated handling, hygiene, product protection and asset traceability.

"Fruit Attraction brings together many of the businesses shaping the future of the fresh produce supply chain, making it the ideal setting to discuss practical solutions to today's challenges," said Laurent Le Mercier, EMEA President at Tosca. "The euro-size Tosca Circular Pallet (CP1208) demonstrates how reusable transport packaging can help businesses improve food safety, efficiency, support compliance with evolving regulations such as PPWR and reduce waste, all while maintaining the performance required in modern supply chains. Together with Cabka, we are helping customers turn circularity into a practical advantage across their operations."

Integration with automated handling systems

The CP1208 measures 1200 × 800 mm and is designed for integration with euro-size pallet handling equipment, subject to the requirements of each installation. Tosca says the standardised platform provides the dimensional consistency and reliability needed in automated, large-scale operations. Rounded skid edges are intended to reduce impact points and minimise damage during forklift handling compared with conventional square skid designs.

"Our contribution is to turn recycled plastics into durable transport products designed around customers' operational needs. With this pallet, we have combined Cabka's expertise in materials and product engineering with Tosca's experience in pooling. Together, we are putting recycled materials to work in demanding fresh produce supply chains," said Alex Masharov, CEO of Cabka.

The pallet has been developed to work with Tosca's reusable plastic crates. Grooves integrated into the deck lock the crates in place without strapping, supporting stable double-stacked transport and load handling. RFID integration is also available to support traceability, asset management and supply chain visibility.

Recycled material, hygiene and handling safety

The non-porous and splinter-free pallet is designed for cleaning in FMCG, grower and retail environments, where hygiene, product protection and repeatable quality are important. Its construction uses an exclusive blend of recycled plastics. Integrated drainage holes prevent water accumulation and limit moisture retention, helping to reduce contamination and product damage while maintaining consistent operation in automated storage and retrieval systems.

The ergonomic design includes smoothly integrated handles positioned in the top deck, as well as stability and anti-slip features. These elements are intended to improve handling safety in warehouses, packing stations and retail distribution centres. According to Tosca, the plastic pallet is more than 4 kg lighter than conventional wooden pallets, making it easier to lift and move during routine operations.

Tosca also links the lower weight and ergonomic design to the social pillar of ESG. Reduced handling effort may limit physical strain and lower the risk of injuries associated with manual pallet movement.

"In high-throughput environments, efficiency and worker safety go hand in hand," said Le Mercier. "By improving stability, grip and ease of handling, the euro-size Tosca Circular Pallet (CP1208) helps reduce manual strain and the risk of musculoskeletal injuries, creating safer working conditions while supporting operational performance."

Preparation for PPWR and EPR requirements

The product was designed with the EU Packaging and Packaging Waste Regulation (PPWR) and extended producer responsibility (EPR) requirements in mind. As these rules reshape packaging and logistics strategies, supply chains increasingly require reusable and traceable packaging with recycled content. Unlike wooden pallets, which may be subject to ISPM 15 heat treatment or fumigation requirements, the CP1208 provides a reusable plastic alternative intended to support the regulatory transition.

Made entirely from recycled plastic, the pallet can be repaired and reused before being recycled at the end of its service life. Tosca says its durability and modular repairability can reduce the total cost of ownership and limit waste associated with short-lived, single-use assets. The pallet is offered within the company's pooling and asset management model.

"At Tosca, we don't simply supply a pallet," concluded Le Mercier. "We partner with customers to manage assets and deliver supply chain performance, meet regulatory requirements, and turn circularity into a lasting competitive advantage."

The CP1208 is intended for manufacturers in the food, beverage and non-food sectors. By combining circular product design with pooling and asset management, Tosca aims to support operational performance, regulatory compliance and long-term supply chain sustainability.