A Breakthrough in Refill and Reuse Systems

The Refill Coalition has successfully demonstrated the viability of its innovative refill and reuse solutions, marking a significant step toward reducing the 90 billion units of single-use plastics sold annually by UK grocers. Following an extensive trial period, the coalition is set to share its findings through an industry webinar and a white paper, accompanied by an independent Lifecycle Assessment (LCA) to be published in May 2025.

The Refill Coalition: A Unified Effort

Established in 2020 and backed by Innovate UK, the Refill Coalition comprises Ocado Retail, Aldi UK, and supply chain solutions provider CHEP. Convened by GoUnpackaged, a leading expert in refill and reuse, the coalition aimed to develop practical, scalable solutions to tackle the plastic waste crisis.

Two pioneering refill models were tested:

• Online Refill with Ocado: Customers received pre-filled reusable containers with their grocery orders, returning them to drivers when empty. Each container replaced up to five single-use plastic packs.
• In-Store Refill with Aldi: Standard bulk dispensers were replaced with reusable vessels at refill stations. Customers brought their own packaging and used an improved weighing system. Each vessel replaced up to 24 single-use plastic packs.

Consumer Response and Market Impact

The trials revealed a strong consumer appetite for sustainable shopping alternatives. Ocado’s reuse system, available to 65% of its customers since August 2024, received high satisfaction ratings, with pasta scoring 4.9 and rice 4.8 out of 5. The sales share of refillable options reached 16% compared to their single-use counterparts. According to customer research, hygiene satisfaction reached 100%, ease of use was rated at 99%, and 96% of participants indicated they would buy again.

Similarly, Aldi’s in-store refill stations, trialed in Solihull and Leamington Spa, saw refills account for 30% of sales alongside packaged versions, peaking at 50% in certain weeks. Customer satisfaction was also high, with 96% approving hygiene, 93% praising speed, and 89% finding the system easy to use.

Environmental and Industry Implications

Early findings from Eunomia’s independent LCA suggest that both refill models offer substantial environmental benefits when scaled, reinforcing their potential as long-term alternatives to single-use plastics.

The coalition initially aimed to establish a standardized refill system across multiple retailers. While this was not fully realized within the trial period, UK retailers have identified this approach as the ‘next generation’ of refill solutions. As the trial concludes, Aldi UK will assess the data and refine its refill and reuse strategy.

Meanwhile, industry-wide collaboration continues, with WRAP (the Waste and Resources Action Programme) spearheading ‘Plastics Pact Mark II.’ This initiative aims to establish standardized principles for reuse, reflecting growing commitment across the sector.

A Call for Industry-Wide Adoption

Reflecting on the trial’s success, the Refill Coalition stated:

“We are extremely proud of our collective work to design and launch these new reuse & refill systems, which form a key part of the solution to tackling the single-use plastics crisis. The trial demonstrates the solutions’ operational efficiency, clear environmental benefit and scalability, which are critical steps towards industry transformation. Additionally, the sales share and in-depth research provide evidence of the significant consumer appetite for availability of refill and reuse as part of their regular shop. We look forward to seeing other retailers and brands taking up these proven solutions, enabling an acceleration towards a reuse future.”

Paul Davidson, Challenge Director at Innovate UK’s Smart Sustainable Plastic Packaging Challenge, emphasized the broader impact of the initiative:

“This collaborative, full supply chain project has successfully developed and trialed an end-to-end solution for refill in the grocery sector, both in-store and online, and we are delighted that the Ocado trial is set to continue. As a result of the innovative approach and hard work of the Refill Coalition partners, we now have a blueprint for retailers looking to mainstream refill within their operations and take action on reducing single-use packaging.”

The Future of Refill and Reuse

With the Refill Coalition’s work paving the way for more sustainable packaging solutions, the next step is industry-wide adoption. The positive reception from both retailers and consumers signals a shift toward a circular economy where single-use plastics are no longer the norm. As stakeholders across the sector explore new ways to integrate refill systems into mainstream operations, the potential for a more sustainable future is within reach.