The Northamptonshire Healthcare NHS Foundation Trust (NHFT) in the UK has introduced a new reusable packaging system across its seven hospital cafés, in partnership with Borealis and FSG Returnables.
The initiative replaces single-use compostable cups with reusable polypropylene alternatives as part of the NHFT’s efforts to limit environmental impact and manage costs over the long term.
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The shift will also curb long-term costs, as reusable and easily recyclable packs are expected to qualify for lower “green-rated” fees under the UK’s Extended Producer Responsibility rules.
Before implementing this scheme, the NHFT relied on single-use compostable packaging for drinks in its cafés.
Despite being marketed as an environmentally friendly solution, these items still generate considerable waste and carbon emissions from manufacturing through to disposal, while also incurring expenses due to the need for constant restocking.
NHFT deputy general manager Joanne Fitzgerald said: “This has been an incredible step forward by NHFT in our journey to protect the planet.
“With the expertise of Lynn Johnson from FSG, we’re moving closer to our net zero goals. Six sites are now running like a sustainability powerhouse, and the transition has been seamless.”
Manufactured using Borealis’ Daploy high-melt-strength portfolio and Bockatech’s EcoCore technology, the new polypropylene cups are designed to withstand a minimum of 1,000 wash cycles in NHS-grade industrial washers.
Their mono-material construction allows them to be recycled within existing systems once they reach the end of their usable life.
The initial rollout included a temporary reward scheme using tokens to encourage staff and visitors to adjust to the new process, supported by clear onsite communication.
Users were given the option to keep, clean and reuse their cups or return them for washing.
Borealis said that participation rates remained high even as reliance on incentives decreased over time.
Projections suggest that, over three years, the scheme will see 898 reusable cups take the place of approximately 175,500 disposable ones and save the NHFT an estimated £27,582 in costs.
Borealis marketing consumer products vice-president Peter Voortmans commented: “Projects like this show what’s possible when circular systems are supported by high-performance materials. That’s why we’ve invested more than €100m to expand our Daploy high melt strength polypropylene production in Burghausen, Germany.
“It ensures our partners have reliable access to fully recyclable, lightweight materials that make reuse systems like this practical, affordable, and scalable.”
In January, Borealis completed a reusable cup pilot at K 2025, the trade fair for plastics and rubber, held at Germany-based trade centre Messe Düsseldorf.
