Refill Coalition--formed by Aldi UK, Ocado Retail and CHEP, and convened by GoUnpackaged--announces 'scalable, commercially viable’ packaging trial; project trialed two models--in-store refill stations and refill vessels, and online consumer returnables

May 1, 2025 (Packaging News) –

The Refill Coalition has announced the results of the UK’s most comprehensive trial of reusable and refillable packaging systems to date.

Formed by Aldi UK , Ocado Retail and supply chain firm CHEP – and convened by GoUnpackaged, the r Results show how reuse is scalable, commercially viable and in high consumer demand

Supported by Innovate UK’s Smart Sustainable Plastic Packaging Challenge, GoUnpackaged said the trial has successfully demonstrated that scalable and commercially viable reuse systems are ready to go mainstream.

The project trialled two models: In-store refill stations, tested in Aldi stores over a 16 month period in Solihull and Leamington Spa , using modular refill ‘vessels’ integrated into existing supply chains; and online consumer returnables, offered through Ocado.com for eight months to date, where customers receive and return pre-filled reusable containers as part of their regular grocery delivery.

The Refill Coalition project showed that with maximum sales shares on a given week of 57% for in-store and 43% for online, without ‘disrupting operations’.

Key Findings from the trial include:

• Strong consumer demand
• In-store refill sales peaked at 57%, averaging 30% of sales share.
• Online reuse products reached up to 43% weekly sales share, averaging 16%.
• High customer satisfaction
• 97% of Aldi users rated the refill experience hygienic; 89% found it easy to use.
• 100% of Ocado users said packaging was clean; 96% would buy again.
• Products consistently received 4.8-4.9 star ratings on Ocado.com.
• Proven operational efficiency
• Aldi staff found restocking refill stations simple and quick.
• Ocado’s model fitted seamlessly into its existing logistics, with vessel return rate reaching an impressive 86% without deposit incentives.
• Environmental impact:
• Independent Life Cycle Analysis showed at scale the reusable vessels can perform better environmentally than the single-use alternatives after as few as two reuse cycles.

Catherine Conway , founder, GoUnpackaged, said: “We are extremely proud of our collective work to design and launch these new reuse and refill systems. They offer a clear path toward tackling the single-use plastics crisis, delivering tangible benefits across environmental, operational, and consumer metrics.”

Giles Hurley , chief executive, Aldi UK & Ireland , said: “This trial marks a significant milestone for sustainable retail. The results show that customers are not only ready for reuse – they’re demanding it. We’re excited to explore how we can take this further.”

The Refill Coalition is now calling for other retailers, brands, and policymakers to get behind these solutions and start adopting these proven models to move the reuse sector forwards.

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