A custom-made 14 litre HDPE reusable container, manufactured by Berry Global, is at the forefront of a new refill packaging solution from the Refill Coalition. This innovative solution was first introduced at Aldi UK in its Solihull branch on October 23rd. The container plays a key role in delivering refills at scale for essential food staples, with plans to expand into household products in the near future.
The Refill Coalition, which consists of Aldi UK, Ocado Retail, and CHEP, a supply chain solutions company, was formed in 2020 by GoUnpackaged, the leading refill experts in the UK. The coalition aims to create a standardized supply chain solution for refills, reducing single-use packaging waste.
The in-store retail refill system involves filling the Berry vessel with the product, which is then delivered to the store and placed in the specially designed refill station. Once empty, the container is returned to be washed and refilled. This approach offers scalability and removes the refill process from individual stores, freeing up space in each retail outlet.
Berry developed a highly specific solution for the in-store system. The container’s angled shoulder design ensures complete evacuation of the product during refilling by consumers. The divorced carry handle prevents any product from entering and getting trapped inside, making it easy to clean and use throughout the distribution chain. Additionally, the design allows for the incorporation of tracking devices like RFID chips or QR codes for product management.
HDPE was chosen as the most suitable material for its durability and ability to withstand the repeated washing and distribution process required for refilling. Although the mono layer construction is currently made from virgin HDPE, the Refill Coalition plans to introduce post-consumer recycled (PCR) materials in the future, aligning with Extended Producer Responsibility requirements.
Berry’s technical expertise was instrumental in successfully developing the vessel. The unique angled neck shape required specialist in-mould cutting during the container’s manufacturing process, a procedure typically done post-moulding for more conventional shapes.
In addition to the in-store refill system, Ocado Retail will launch a bulk home delivery refill solution in early 2024, for which Berry has also developed a custom vessel. The 3-litre version of the container is designed to fit the delivery crates used by Ocado Retail. With two neck sizes available, 60mm and 80mm, and closures supplied by Berry, separate containers for dry and liquid products can be utilized.
Refill solutions address the issue of single-use packaging waste. According to the Refill Coalition, if every household in the UK refilled just one item per week, over 1.4 billion single-use packs could be eliminated in a year*.
“Plastics’ versatility has been key to the success of this project,” said Edward Arnold, who has coordinated the project for Berry alongside its customer CHEP.
“We were able to select a polymer that is robust enough for multiple reuse, lightweight for easy handling and to minimize carbon emissions during transportation. Plastic also provides the design flexibility required to create two distinct and effective refill systems.
“Designing for reuse is a crucial component of Berry’s Impact 2025 sustainability strategy. This innovative refill solution demonstrates what can be accomplished when all segments of the supply chain collaborate, and we are proud to partner with CHEP and the Refill Coalition to bring it to fruition.”
The Refill Coalition’s solution is designed as a global standard that can be adopted by any supplier or retailer, enabling widespread availability of refills across the UK. Following the success of this pilot program, coalition retailers will roll out refill stations in their stores and online.
“I am thrilled to see our collective vision with Berry and other partners of the Refill Coalition being introduced and tested in this pilot,” said Katrin Zeiler of CHEP.
“At CHEP, our business model is centered around a sustainable circular economy of sharing and re-use. This pilot represents our commitment to redefining industry standards, reducing single-use packaging, and fostering a regenerative supply chain that contributes to our sustainability goals.”
For further information, visit our website, or connect with us on LinkedIn or Twitter.
Photo courtesy of GoUnpackaged
