Berry has developed a new 14 litre HDPE reusable container for the Refill Coalition. A pilot project with the new solution was launched at an Aldi UK shop in October.
The Refill Coalition is made up of Aldi UK, Ocado Retail and the supply chain solutions company Chep and was launched in 2020 by GoUnpackaged, the UK's leading expert in refill products. As part of the refill project, a standardised solution for the entire supply chain to ensure large-scale refills for key staple foods such as cereals and pasta. to deliver. In the near future, household products such as cleaning agents and personal care products will also be included.
With the refill system for the retail trade, the product is placed in the Berry-containers and delivered to the shop, where it is placed in the Specially developed refill station is used. When the container is empty, it is returned for washing and refilling. This solution offers economies of scale and takes the refilling process away from individual shops, freeing up space in each outlet.
For the in-store system, Berry has developed a solution for a very specific task. The Inclined shoulder design of the container ensures that the entire product is emptied when refilled by the consumer becomes. A split carry handle prevents the product from penetrating and getting stuck in the handle and facilitates cleaning, while being easy to use throughout the distribution chain. The design also allows the Integration of an RFID chip, QR code or similar device for tracking and product management.
HDPE was chosen as the material due to its robustness and durability to withstand the repeated washing and distribution process to enable the multiple uses required for the refill process. While the single-layer construction - which facilitates recycling at the end of the container's life - is currently made of untreated HDPE, the Refill Coalition plans to make the container with post-consumer recyclate (PCR) in the future, which will support compliance with the requirements of extended producer responsibility in the supply chain.
Berry's technical skills were also crucial to the successful development of the container. The special shape of the angled neck required special cutting in the mould, to create the opening in the container - a process that is usually carried out after casting in more traditional moulds.
In addition to the in-store refill system, Ocado Retail will also be launching a Launch refill solution for home delivery of bulk packs, for which Berry has also developed a special container. The 3 litre version of the container has been designed to fit into the delivery boxes used by Ocado Retail. Two neck sizes, 60mm and 80mm, with closures also supplied by Berry, mean that there can be separate containers for dry and liquid products.
„The versatility of plastics was critical to the success of this project. We were able to select a polymer that was robust enough for multiple reuse, while also providing a lightweight solution for ease of handling and to minimise the carbon impact of transportation. Just as importantly, the plastic has the design flexibility to create two specific and completely different designs for both refill systems. Designing for reuse is one of the key elements of Berry's Impact 2025 sustainability strategy and commitments. This innovative refill solution shows what can be achieved when all parts of the supply chain work together and we are very proud to have worked with Chep and the rest of the Refill Coalition to bring it to life.“
Edward Arnold, who coordinated the project for Berry
The Refill Coalition's solution has been designed as a global standard that can be used by any supplier or retailer, allowing the industry to quickly access it to provide refill stations to any customer in the UK. Subject to the success of this initial trial, the Coalition's retailers will roll out refill stations in-store and online.
„I am thrilled that our shared vision with Berry and other Refill Coalition partners is being showcased and tested in this pilot project. At Chep, our business is driven by our sustainable circular economy model of share and reuse. The pilot represents our commitment to redefine industry standards, reduce single-use packaging and promote a regenerative supply chain to achieve our sustainability goals.“
Katrin Zeiler, Chep
Source: Berry
