Viscount New Zealand has eliminated the equivalent of more than 200 million single-use cardboard boxes through the growing adoption of reusable plastic crates, demonstrating how circular packaging systems are transforming the way food moves from farm to retailer. 

Viscount operates a national pool of 1.5 million reusable produce crates, which circulate continuously between growers, packhouses, transport operators and supermarkets. Each crate is designed to be reused around 140 times over its lifespan, replacing the equivalent of 140 disposable corrugate boxes. 

According to Regan Hill, General Manager of Viscount New Zealand, the scale of reuse now operating across the sector highlights how practical solutions can deliver both environmental and operational benefits.

 “Reusable packaging is one of the most effective ways the produce industry can reduce waste before it’s created,” Hill said. “When you look at the scale of New Zealand’s produce supply chain, small operational improvements quickly add up to significant environmental outcomes.”

Across Viscount’s national crate pool, the reuse system represents the equivalent of more than 200 million single-use cardboard boxes avoided, significantly reducing packaging waste while also improving logistics efficiency.

Unlike disposable cardboard cartons that are used once and discarded, reusable crates circulate continuously through the supply chain. Once emptied at distribution centres or supermarkets, they are returned, washed, sanitised and sent back into circulation for the next cycle. 

Hill said the shift toward reuse is delivering measurable benefits not only for produce, but across broader food categories.

“While fresh produce has led the way, the same principles apply across sectors like eggs and poultry, where product protection, hygiene and consistency are critical,” he said. “Reusable systems help improve handling efficiency, reduce damage and create a more controlled, reliable supply chain.”

Purpose-built for demanding food environments, Viscount’s reusable solutions are designed to optimise performance across multiple categories. From improved airflow and temperature management to durable construction and efficient return logistics, the system supports both product integrity and operational efficiency at scale.

Hill said the success of reuse in New Zealand reflects strong collaboration across the supply chain and signals a broader opportunity for other sectors to follow.

“Reuse only works when growers, producers, logistics providers and retailers work together. What we’re seeing now is a proven model that can be extended beyond produce into other parts of the food system,”  he said.

As pressure continues to grow on businesses to reduce packaging waste, emissions and supply chain costs, Hill believes reuse will play an increasingly important role across New Zealand’s food and retail sectors.  

“This is about preventing waste before it is created. When reuse systems are designed properly and operate at scale, they deliver better outcomes for business, for supply chains and for the environment.”

The scale of reuse now operating in New Zealand demonstrates how circular packaging systems can move beyond theory and deliver measurable impact — with the potential to transform multiple sectors across the food industry.