Converting Fresh-Cut Salads to Reusable Plastic Crates
Case Study
1 August 2026
Converting Fresh-Cut Salads to Reusable Plastic Crates
The Challenge
The fresh-cut salad category has long been one of the most difficult segments to transition from single-use corrugated cardboard to reusable plastic crates (RPCs).
Growers face unique supply chain demands. Fresh-cut salads require fast turnaround times, chilled distribution and consistent product protection from packing through to retail. For many years, corrugated cardboard has remained the default packaging choice despite ongoing operational challenges.
Single-use cardboard can become compromised in cold and high-moisture environments, increasing the risk of carton damage, product loss and handling inefficiencies throughout the supply chain. It also creates ongoing waste, requires continual replacement and is not well suited to the increasing levels of automation being adopted by major retailers.
“RPCs help us deliver fresher bagged salads to consumers by improving airflow and temperature control throughout the supply chain, supporting both product quality and waste reduction.”
The Results
Use of Viscount’s reusable plastic crate pooling network commenced in August, successfully converting fresh-cut salad volumes into a reusable packaging system.
The project represent an important breakthrough for Viscount, demonstrating that one of the industry’s most challenging categories can successfully transition away from single-use packaging.
1400000
Single-use cartons removed
532
CO₂ emissions reduction
Tonnes CO2 eq
181
Waste reduction
kg PM2.5 eq
5428685
Water reduction
L water eq
How we got there…
The Opportunity
One of Australia’s leading fresh produce businesses recognised the need to future-proof their operations by moving to a more efficient and sustainable packaging solution.
Working in partnership with Viscount, they made the transition to reusable plastic crates for their fresh-cut salad operations, marking a significant milestone for the category.
The Solution
Viscount’s reusable plastic crate pooling solution provided a circular alternative to single-use cardboard, designed to improve operational performance across the entire supply chain.
Key benefits include:
- Durable crates that maintain their strength in chilled and humid environments.
- Consistent dimensions for improved handling and compatibility with automated distribution centres.
- Better product protection, helping reduce packaging failures and product damage.
- A hygienic, washable solution that is cleaned, sanitised and quality checked after every use.
- Elimination of single-use cardboard waste through a reusable pooling model.
- End-to-end pooling, collection and washing services that simplify asset management for growers.
By integrating seamlessly into existing retailer supply chains, the transition was achieved with minimal disruption while delivering long-term operational benefits.
Looking Ahead
As retailers continue investing in automation and circular supply chains, reusable plastic crates are becoming increasingly important across fresh produce.
This successful conversion provides a blueprint for the wider fresh-cut salad industry, proving that growers can improve efficiency, reduce waste and better meet future retailer requirements through reusable packaging.
Together, these partnerships are helping pave the way for a more resilient, sustainable and circular fresh produce supply chain.
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