Image: Marek Piwnicki via Unsplash
Aldi and Ocado are leading the way in reusable packaging innovation, with trials carried out under the Refill Coalition led by GoUnpackaged. The results speak for themselves: refill rates in stores reached up to 57%, while return rates for reusable containers hit an impressive 86% – all without relying on deposit schemes. These figures demonstrate that well-designed reuse systems can not only meet expectations but exceed them, Circular reported.
An independent life cycle analysis found that reusable containers surpass single-use plastic after only two uses.
Aldi conducted a 16-month trial of in-store refill stations at its Solihull and Leamington Spa stores, introducing modular vessels that were engineered to fit smoothly into the company’s existing logistics infrastructure. These vessels were expected to replace up to 24 single-use plastic packages each. Meanwhile, Ocado rolled out a complementary solution through its online grocery service, offering customers returnable containers alongside their regular orders. This model was anticipated to reduce the need for approximately five single-use packages per item.
Aldi’s refill stations reached up to 57% usage, averaging 30% of sales, while Ocado’s online reuse containers peaked at 43%, with a steady 16% share. Shoppers embraced the systems – most rated them highly for hygiene and ease of use, with 96% of Ocado users willing to repurchase. Product ratings averaged 4.8 to 4.9 stars.
The project was supported by Innovate UK’s Smart Sustainable Plastic Packaging Challenge. Aldi concluded its pilot in March, attributing the closure to the end of grant funding and a lack of broader industry engagement, which hindered further rollout.
According to the Refill Coalition, the trial proved the model’s operational efficiency, environmental impact, and scalability – key elements for driving industry change. Strong sales performance and consumer research also confirmed clear demand for refill and reuse in everyday shopping.
Several major UK retailers – including M&S, Morrisons, Waitrose, Sainsbury’s, and Lidl – participated in the project’s early phases. The strong results from these pilots reflect a growing global momentum, with companies like Unilever running large-scale reuse initiatives in South Asia aimed at cutting sachet waste and providing more accessible refill solutions.