Cardboard produce boxes or plastic crates? In the fresh produce sector both systems exist side by side, and neither is the best choice in every situation. The right answer depends on your product, your customers and how your supply chain works. In this article we lay out the differences honestly, so you can make a well-founded choice.
Two systems, two logics
Plastic crates are reusable. They often circulate in a pooling system: the crate is delivered, filled, shipped to the retailer, collected, washed and used again. You pay per rotation or rental, and the crate comes back.
Cardboard produce boxes are single-use. The box is made to measure, filled, delivered and recycled after use. There is no return flow: the box leaves your company and does not come back.
That difference in logic drives almost every advantage and disadvantage.
Where plastic crates are strong
- Reusable: one crate lasts many rotations, which in a well-run pool means less packaging material per delivery.
- Sturdy and moisture-proof: plastic is not affected by wet produce, cold rooms or condensation.
- Standardised: fixed formats that fit the systems of large retailers.
But: a pooling system requires return logistics, washing, deposit or rental administration, and follow-up of lost or damaged crates. For exporters, smaller growers or customers outside the pool, that often outweighs the benefit.
Where cardboard produce boxes are strong
- No return logistics: no empty crates to collect, wash or track. Ideal for export and for deliveries to multiple customers.
- Made to measure: dimensions, ventilation holes and strength are matched to your product and pallet pattern. No wasted space, no shifting fruit.
- Your brand on the box: flexo or offset print, up to full colour. The box carries your brand from field to shelf.
- Lightweight: less weight per pallet, so lower transport costs.
- Recyclable: cardboard is collected and recycled at scale in Belgium and the Netherlands, and is available with FSC certification.
- Hygienic: every delivery starts with new, clean packaging.
But: cardboard is sensitive to moisture. For cold storage, wet produce or long cold chains, the right grade is essential: double flute (EB), solid board or a moisture-resistant coating. For extreme stacking heights, the box must be designed for that load.
At a glance
| Cardboard produce box | Plastic crate | |
|---|---|---|
| Use | Single-use, then recycled | Reusable (pool) |
| Return logistics | Not needed | Needed (collection, washing, admin) |
| Format | Fully made to measure | Fixed standard formats |
| Print / branding | Up to full colour | Limited (label) |
| Moisture resistance | With the right grade or coating | Very good |
| Weight | Light | Heavier |
| Best for | Export, multiple customers, branded produce | Fixed, closed loops with one retailer |
Which one fits you?
Lean towards cardboard if:
- you export or supply several customers;
- you want your brand to stand out in store;
- your product needs a specific format or presentation;
- you don’t want to spend time or space on return logistics.
Lean towards plastic crates if:
- you mainly supply one retailer that works with a pooling system;
- the crates stay within a fixed, closed loop;
- branding on the packaging plays no role.
Many companies combine both: crates for the fixed retail flow, cardboard for export, premium lines and seasonal products.
Keep an eye on regulation
The new EU Packaging and Packaging Waste Regulation (PPWR) sets stricter requirements on recyclability and reuse of packaging in the coming years, including in the fresh produce chain. What that means in practice depends on your product, your customers and the type of packaging. Get properly informed before investing heavily in a single system.
Tailored advice for your produce packaging
J&S Packaging supplies cardboard fresh produce packaging to growers, auctions, exporters and processors: produce boxes, trays, crate cards and paper tray liners. Together we work out the solution that fits your product and your chain.
Book a free consultation call or request a no-obligation quote.