You need to boot your old plug and copy the entire "approot" directory (recursive copy) from the path /root/app/tonido/ to place it in the new plug at the same path.
After doing this you need to restart tonido. This can be done either on the plugadmin UI or running the following command
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# initctl emit tstop # to stop tonido
# initctl emit tstart # to start tonido
BTW, if you are going to use a USB stick with non unix formats (such as FAT) please tar the directory on the old plug, copy the tar to the new plug and untar it. This is because copying directly onto a non unix format disk will make the directories lose its permissions.