Study evaluates the impact of transport packaging solutions on store labor

Tosca, a manufacturer of reusable packaging and supply chain solutions for perishables, commissioned industrial engineering firm, Advantage Consulting to conduct a study evaluating the impact of transport packaging solutions on store labor.

The study, Time and Motion Study, compared the time it takes to stock and manage egg displays in a grocery store using traditional one-way corrugated shipping boxes versus Tosca’s Reusable Plastic Containers (RPCs).*

The methodology for comparison analyzed the multi-step process for managing the egg department including: pulling egg cases from the cooler, stocking and rotating cartons, disposing of packaging and removing damaged eggs.

Findings from the Time and Motion Study show:

• It takes less than half the time to stock an egg display using retail-ready RPCs instead of corrugated. On average, in an 8-ft display case, RPCs stock and rotate product in 10 min versus 21 min for corrugated packaging.

• Taking advantage of timesaving RPCs, retailers will see a 53% reduction in labor to manage the egg category.

• Using RPCs, each store will save five days and 16 hr in labor each year. This labor can be reallocated to other tasks.**

Additionally, the study found that when using corrugated, removing egg cartons from boxes and stacking them in the display case has significant impact on stocking time (35%) while rotation of product is another important factor in stocking time (24%).

With Tosca’s retail-ready solution, eggs can be displayed directly in its custom designed RPCs, eliminating the time-consuming tasks of removing, stacking, and rotating egg cartons. Tosca’s unique one-step SmartWallTM design simplifies restocking and saves labor by allowing employees to place the container directly in the case and drop the front wall for display in one easy motion.

Additionally, it’s easier and faster to rotate merchandise when cartons are in RPCs versus stacked individually. Managing the egg display with corrugated means handling individual cartons for rotating stock versus RPCs that move 24 cartons at one time. RPCs can be removed from the display case, newer product in RPCs can be added to the display, and then the RPC with the earliest expiration date can be placed in front.

“We know that retailers are looking for a better way to identify cost and labor savings, improve supply chain efficiency and protect the product quality of perishables,” said Eric Frank, president and CEO of Tosca. “This study helps validate that there is a better way to move eggs safely and efficiently from source to shelf. RPCs not only are easier and faster to stock but also help reduce shrink by offering the best protection available for fragile eggs.”

* The Tosca Time and Motion Study was conducted in regional grocery stores in the Midwest in 2018. Over two separate one-week periods a third-party engineer traveled to each store and studied the time it takes to stock and rotate eggs in a display cooler, the first week using traditional corrugated shipping boxes and the second week using reusable plastic containers (RPCs).

**Based on stocking an 8-ft display twice a day.

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