Material, safety, logistics, certificates and regulations — detailed answers for every part of your business.
Polypropylene is the dominant material in reusable food packaging today because it combines three properties that no other material offers simultaneously.
Non-porous structure — PP's molecular network leaves no room for absorption of liquids, odours or bacteria. Unlike wood and cardboard, PP absorbs nothing from food.
Chemical inertness — PP does not react with acids, oils, salts or organic compounds released by food. There is no migration of chemicals into food even with prolonged contact.
Mechanical resistance — the material returns to its original shape after loading, allowing 250+ cycles without degradation. Wood wears out, cardboard deteriorates, PP stays the same.
HACCP certification for packaging confirms that the material does not migrate chemicals into food above permitted limits, does not change the taste, odour or colour of food, and is produced in a controlled process without contamination.
When sanitary inspection comes to check your facility, packaging must be documented. HACCP certification for packaging is part of your facility's HACCP plan; without it, you have a non-critical control point that can result in a finding.
Certificates supplied by CASHETICA are accepted for sanitary inspections, public procurement (hospitals, kindergartens, schools) and requirements of retail chains and distributors.
The purchase price of packaging is only one part of the cost. The full picture includes costs that are rarely summed up:
| Cost | Single-use | PP crate |
|---|---|---|
| Procurement | visible | visible |
| Removal and disposal | hidden | negligible |
| Damaged goods (moisture, puncture) | hidden | negligible |
| Packing man-hours | hidden | –40 to 60% |
| Empty packaging space | hidden | –80% (foldable) |
Cost per cycle is the only metric that shows the real cost: purchase price divided by number of uses. A crate of €10 / 250 cycles = €0.04 per use, which is 4 to 6 times cheaper than cardboard.
Pooling is a shared use model where crates are not owned by one entity but circulate through a closed system between suppliers, distributors and retailers.
The cycle looks like this: supplier fills crates, sends them to customer, customer returns them empty, crates go to washing, then return to supplier. No capital investment in inventory, no stock management.
The pooling model is used by all major European retail chains — Lidl, Kaufland, Rewe and Carrefour operate with over 300 million crates in circulation through Ifco and CHEP pooling systems.
Reverse logistics (returning empty packaging) is one of the biggest hidden costs in fresh food distribution.
One Euro pallet holds 40 open crates. Folded, it holds 256 crates on the same pallet. That is 6.4 times more crates per pallet.
For a deliverer returning 500 empty crates weekly: with open crates, 12 to 13 pallets are needed, while with folded ones only 2 pallets. Two Euro pallets can be transported together with regular delivery, without a separate return trip.
Crates are made of copolymer PP which retains flexibility down to –25°C without brittleness. Standard PP becomes brittle below –10°C, but ethylene-propylene copolymer disrupts chain crystallization and prevents cracking.
A critical moment for packaging is moving from cold storage to a warm room. Cardboard softens, wood absorbs moisture and becomes a breeding ground for bacteria. PP crate forms condensate only on the surface, and the perforated bottom drains it immediately.
Our crates are produced from polypropylene (PP) in a controlled, professional process. Certified raw granulate is used, material is melted and shaped in closed machines without contact with food during production. The process is fully repeatable and controlled.
PFAS ("forever chemicals") are a special group of synthetic chemicals used in non-stick, water-repellent and grease-resistant coatings. They are most commonly found in paper and cardboard packaging with grease-resistant coating, coatings for pans and kitchenware, and special industrial coatings. Polypropylene does not use PFAS compounds nor require them for its function. PP is a structural plastic that owes its properties exclusively to the polymer network, not chemical coatings. Compared to some types of paper packaging, PP is therefore considered a safer and more stable solution for reuse in the food industry.
BPA (bisphenol A) is a monomer component of polycarbonate (PC) and epoxy resins — not polypropylene. PP by chemical structure cannot contain BPA. Polypropylene is approved for direct food contact according to EU Regulation 10/2011 and FDA, and is widely used for infant products. BPA is associated with other types of plastic, but not with PP.
Absorption of odours and moisture: PP is a non-porous material. Liquids, oils or volatile organic compounds that cause odours do not pass through the dense polymer network. For bread and pastries, this is especially important because PP does not create conditions for mould growth, does not retain condensation and does not change the taste or smell of the product.
| Material | Porosity | Absorbs odours | Mould growth |
|---|---|---|---|
| Polypropylene (PP) | None | No | No |
| Wood | High | Yes | Yes |
| Cardboard | High | Yes | Yes (when moist) |
| HDPE | Low | Minimal | No |
The EU Packaging and Packaging Waste Regulation (PPWR) replaces the old Directive 94/62/EC and sets significantly stricter requirements coming into force gradually from 2030.
Key upcoming obligations: certain categories of B2B packaging for fresh food will have to be available in a reusable variant, all packaging must be 100% recyclable, and waste disposal costs fall on the producer or importer.
Polypropylene is a 100% recyclable thermoplastic that can be processed into new granulate. PP crates meet all foreseen EU criteria for recyclability and reuse.
Operational programmes for green transition (NPOO, Cohesion Funds 2021–2027) recognise investments in reducing packaging waste as eligible costs in projects for logistical improvements, waste reduction and circular economy.
Purchase of reusable PP crates can be presented as a measurable investment in reducing single-use waste (tons less waste annually), compliance with PPWR regulation and reduction of CO₂ emissions in logistics thanks to foldability and fewer return trips.
According to an LCA study published in an international peer-reviewed journal (Springer, 2020), PP crates show a 55 to 70% lower total carbon footprint than single-use cardboard alternatives per functional unit of 1,000 transport cycles.
PP is a non-porous material that does not absorb bacteria or liquids, so washing is simple: rinsing under a stream of warm or cold water with mild detergent. For disinfection, you can use standard food disinfectants. For larger fleets, we offer industrial washing options.
Crates can be used for different types of food after proper washing. PP does not retain odours or residues, so there is no risk of cross-contamination when the crate is clean.
Many customers prefer a colour-coding system by food categories: green for fruit and vegetables, orange for meat and fish, white for bakery products. CASHETICA crates are available in both standard colours.
The smooth outer surface of the crate is compatible with several labelling methods used in food distribution:
For companies operating with a larger number of crates in rotation, RFID integration allows automatic tracking of position and number of cycles of each crate — which directly supports ESG reporting on waste reduction.
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