Reusable food primary packaging in retail supply chain: A multi-objective optimization framework

The increasing demand for sustainable and equitable raw material utilization underscores the potential of reusable packaging as an effective solution. The food retail sector, a significant contributor to packaging waste, faces a clear need for comprehensive decision support systems to manage the complexities of reusable packaging circular networks. Managing these networks requires balancing environmental efficiency with economic viability, considering enabling conditions like consumer return attitude, packaging design properties (weight, size, and stackability), and players' logistic proximity. This paper presents a multi-stage and multi-objective optimization framework designed to select optimal product-package combinations and establish a circular network that encourages the adoption of reusable food packaging in retail. The framework is applied to a significant real-world application consisting of two nationwide retailers in France. The findings confirm that high return rates (>60–70 %) are essential for the viability of the circular system whilst ensuring low scrap rates (<15 %) tip the balance for environmental benefits. Lightweight and stackable packaging solutions enhance resilience in systems with uncertain return and scrap rates. Packaging properties must be evaluated alongside logistics network configuration, as packaging selection is tied to production sites, shaping network adaptability. We introduce a new metric that evaluates packaging and network suitability by assessing packaging weight and transportation distances. A lower value indicates improved resilience and supports the long-term viability of the system. The results emphasize the role of Reusable Vending Machines (RVMs) in reducing environmental burdens, as a higher number of installations leads to greater impact reductions. However, RVM costs account for 70–87 % of differential expenses, depending on deployment scale and budget constraints. To address this, we propose a RVM allocation strategy that optimizes distribution while balancing economic and environmental trade-offs. This multi-objective optimization framework provides valuable insights for policymakers and businesses striving to scale reusable food packaging initiatives effectively.