At Borealis, we’re committed to working with partners to develop circular solutions that work in everyday settings. A recent example is our collaboration with FSG Returnables to enable a large-scale reusable packaging system at Northamptonshire Healthcare NHS Foundation Trust (NHFT), part of the UK’s National Health Service (NHS).
The Trust’s decision to switch to a reusable packaging solution was primarily driven by the need to reduce environmental impact. It also reflected a focus on long-term cost control, as reusable and easily recycling packaging will benefit from lower fees, known as ‘green-rated fees’, under the UK’s Extended Producer Responsibility (EPR) policy framework.
Borealis and FSG Returnables support NHFT in rolling out a large scale reusable cup system.
© Northamptonshire Healthcare NHS Foundation Trust (NHFT)
Previously, NHFT relied on single-use compostable packaging in its cafés. While intended to reduce environmental impact, this approach still generated significant waste, along with carbon emissions linked to production, transport, and disposal. It also created high ongoing purchasing costs, as items had to be continually replaced.
The Trust wanted to move away from this model and introduce a reuse system that could operate reliably across multiple hospital sites. Reducing carbon emissions and long-term costs was essential, but the system also had to remain easy for staff and visitors to use.
The Zero Waste Cup for hot and cold beverages is designed to fulfill multiple uses and returns.
© Borealis
With the support of FSG Returnables, NHFT introduced a reusable food and drink packaging system across all seven of its hospital cafés. For drinks service, the partners chose to use Zero Waste Cups™ made using Borealis polypropylene (PP) from our Daploy™ high-melt-strength (HMS) portfolio and produced using Bockatech’s EcoCore® technology.
The EcoCore foamed polypropylene structure is ultra-lightweight yet still provides the strength and thermal performance needed for hot drinks.
At the same time, the material is designed for durability: the cups perform reliably over more than 1,000 NHS-grade industrial wash cycles and remain stable when exposed to heat, detergents, and frequent handling. Because they are a 100% PP mono-material solution, they can be easily recycled at end of life through existing recycling streams.
“At FSG Returnables, we chose to supply the Zero Waste Cup because of its EcoCore technology and outstanding material performance. The double-walled, foam-insulated design is lightweight yet extremely durable, making it ideal for high-use reuse systems. Using high-quality polypropylene supplied by Borealis gives us confidence in both long-term durability and recyclability.”
Lynn Johnson, FSG Returnables, Managing Director
The system was designed to encourage reuse through simplicity. Single-use cups and containers were fully removed, making reusables the only option. During the initial rollout, a short-term token reward scheme helped people adjust to the new system, supported by clear communication and on-site engagement led by FSG.
The system quickly became established throughout the cafés. Most people chose to keep, wash, and reuse their cups rather than exchange them, and clear processes made returns straightforward for both staff and visitors. Once established, the system relied less on incentives and more on consistency and ease of use to maintain high return rates.
"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. Staff, visitors, and patients alike have embraced this change wholeheartedly!"
Joanne Fitzgerald, NHFT Deputy General Manager
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. It demonstrates that uniting advanced material performance, thoughtful system design, and a practical approach to behavior change can deliver measurable environmental and cost benefits without compromising day-to-day functionality.
Over a three-year period, the reusable cup system is projected to deliver the following results:
The system also aligns with the UK’s EPR framework, positioning NHFT ahead of rising fee modulation that favors reusable and recyclable packaging.
“Projects like this show what’s possible when circular systems are supported by high-performance materials. That’s why we’ve invested more than €100 million 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.”
Peter Voortmans, Borealis Vice President Marketing Consumer Products
Building on this success, NHFT and FSG are already exploring further returnable solutions for the NHS, 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.
Zero Waste Cups are suitable for dishwasher and microwave use.
© Borealis