Brazil is among the top ten countries that waste the most food, with around 35% of production being lost every year, according to data from the United Nations Food and Agriculture Organization (FAO).
An alarming fact is that while globally 14% of food produced is lost between harvest and when it reaches stores, here that number reaches 50%, according to the NGO Food Bank.
To help fresh food retailers reduce carbon emissions, damage, and food losses during transportation and the consequent waste disposal in landfills, the company HB Pooling created a returnable box sharing system for transporting perishables. The packaging is used throughout the food supply chain (producers, distributors, and retailers), promoting circular economy in the sector.
Companies request the desired number of boxes for transporting perishable foods through a system managed by HB itself. The boxes are delivered and, after use, return to HB, where they are sanitized and redistributed to new users, thus creating a continuous sharing cycle.
Major retailers such as GPA, Carrefour, Dia, and Natural da Terra already use HB’s reusable boxes. Over the past five years, the company’s average annual growth has been above 50%.
–> Watch a video about the reusable box usage cycle
According to HB, being returnable, the plastic packaging also eliminates the need to manage the disposal of thousands of single-use packages, resulting in immediate reductions in operational and labor costs for retailers. Additionally, they allow better utilization of pallets and trucks, leading to fewer trips and, consequently, cost savings and lower carbon emissions.
HB’s sustainable practice has already prevented 25 million tons of pulp and cardboard waste (single-use boxes) from ending up in landfills or being disposed of in ways harmful to nature.
A still untapped market
The market potential for returnable packaging solutions is significant. According to HB Pooling CEO Ana Miranda, Brazil handles approximately 7.3 billion kilos of fruits, vegetables, and greens (FLV) per year. Of these, the company estimates only 12% are packed in returnable packaging.
For this year, HB’s projection is optimistic. The company expects to double in size and is already prepared to expand its operations. ‘We will provide the market with an additional 1.2 million reusable boxes, meeting the growing demand for efficient and sustainable logistics solutions in Brazil,’ reveals Ana. Currently, HB has 2.3 million assets in circulation (all produced locally).
Based in Curitiba, HB operates in nine states and serves 30 retail distribution centers and 14 producer supply centers.
Fewer food losses in transportation
Food loss occurs when there is a reduction in the quantity or quality of food before it reaches the markets and other establishments. It happens for various reasons.
In Brazil, fresh food distribution faces critical challenges related to losses and waste, impacting everything from the profitability of producers and retailers to the final quality of products on the shelf and the environment as a whole.
Among the main causes of food losses are inadequate packaging of products in containers (boxes, cardboard, or wood) and excessive handling, both when loading them onto trucks and during the unloading process.
“The use of appropriate packaging that minimizes cargo handling and possible physical damage is a relevant factor for preserving product quality and mitigating losses,” says Ana.
Benefits of Pooling
The service offered by HB is based on the ‘pooling’ concept, still little known in Brazil but widely used in Europe.
It involves sharing packaging for transportation, allowing multiple companies across the supply chain to use the same asset instead of each buying and maintaining their own boxes for food transportation.
The pooling is considered a way to reduce environmental impact because it encourages the reuse and recycling of packaging, contributing to reduced consumption of natural resources and decreased waste generation.
“By using the pooling system, everyone wins: retailers lower their costs and increase efficiency; end consumers get access to fresh food at maximum quality; and the environment suffers less impact,” summarizes Ana.
Main benefits of using returnable boxes
Four times more durable than cardboard boxes—still widely used for FLV transportation—the foldable boxes are made of 100% virgin and recyclable plastic. Being lightweight yet sturdy, they facilitate handling, loading, and unloading of products, ensuring items arrive fresh and intact at their destination. The plastic boxes also do not absorb moisture like wood or cardboard ones.
According to HB, these are the five main benefits of replacing disposable packaging with reusable boxes:
• Circular Economy: reusable boxes are designed for continuous use in the supply chain, minimizing the need for disposable materials. At the end of their life cycle, they are recycled to create new assets, closing the loop and preventing waste.
• Waste Reduction: decrease in solid waste, reducing environmental impact and the supply chain’s carbon footprint.
• Fewer trips, fuel consumption, and 50% more deliveries: the box design allows more of them to be stacked in the same load, better utilizing vehicle space. This results in up to 50% more deliveries due to reduced trips and lower fuel consumption.
• Reduced Food Waste: according to an HB study, when compared to other packaging like cardboard, plastic boxes ensure up to 96% less damage to products during transportation to retailers. This is because their design protects against external impacts and internal friction. Additionally, they reduce transportation waste by 35% due to proper ventilation for contents, allowing better airflow for FLV.
• Less handling and potential damage at POS: products arrive at the POS ready for display, with no time lost unpacking, unloading, or sorting items. They also eliminate the need to transfer items between boxes. All this reduces the chances of food handling damage.
–> Watch here a video demonstrating how HB’s pooling cycle works.
