Northamptonshire Healthcare NHS Foundation Trust (NHFT) has launched a groundbreaking reusable packaging system across its seven hospital cafés, signaling a major step towards reducing waste and cutting costs.

 

“At Borealis, we’re committed to working with partners to develop circular solutions that work in everyday settings,” the company said, highlighting its collaboration with FSG Returnables on the initiative.

 

The Trust’s shift from single-use compostable cups to a reusable system was driven by the need to reduce environmental impact and control long-term costs. Under the UK’s Extended Producer Responsibility (EPR) framework, reusable and easily recyclable packaging attracts lower “green-rated fees,” offering further financial incentive.

 

Previously, NHFT relied on single-use compostable packaging, which still produced significant waste and carbon emissions from production, transport, and disposal. It also meant high ongoing costs as items needed constant replacement.

 

With FSG Returnables, NHFT rolled out a reusable cups system built to last. “Zero Waste Cups made using Borealis polypropylene (PP) from our Daploy high-melt-strength (HMS) portfolio and produced using Bockatech’s EcoCore technology” were selected for the program. 

 

The foamed polypropylene design is lightweight yet durable, able to withstand over 1,000 NHS-grade industrial washes while maintaining stability under heat, detergents, and frequent handling. Being 100% PP mono-material, the cups are easily recycled at end of life.

 

The system encourages reuse through simplicity. Single-use cups were eliminated entirely, and a short-term token reward scheme helped staff and visitors adapt, supported by clear communication and on-site engagement from FSG.

 

The results were immediate. Most users opted to keep, wash, and reuse their cups, and returns became seamless. The system quickly relied more on convenience than incentives to maintain high reuse rates.

 

“This program is among the first large-scale reusable packaging systems implemented within the NHS and is a visible sign of NHFT’s progress toward its Net Zero commitment,” the partners said. It demonstrates how advanced material performance, smart system design, and practical behavior-change strategies can deliver measurable environmental and financial benefits without disrupting daily operations.

 

Over three years, the reusable cup initiative is expected to replace roughly 175,500 disposable cups, using just 898 reusable cups, and generate cost savings of £27,582.

 

NHFT and FSG are already exploring further returnable solutions, including patient meal systems. “At Borealis, we’re proud to support this work and to continue our long-standing partnership with FSG on circular economy solutions in healthcare and beyond,” the company added.