In this article sponsored by RECOUP, the UK’s leading independent authority on plastics resource efficiency and recycling explores if reusable packaging can scale through existing collection systems.
Up to 95% CO₂ reduction could be achieved by switching just 30% of UK plastic packaging to reusable formats, according to new modelling by GoUnpackaged.
Once infrastructure is in place, reuse offers cost advantages over single-use and can support community benefits, such as job creation in local reverse logistics and wash hubs.
Despite the environmental and economic potential, returnable packaging systems remain difficult to scale. Ensuring that packaging is returned to circulation is essential to any successful reuse model. Without convenient, consistent return pathways, even the most innovative reuse systems risk stagnation.
A new report from RECOUP, Buy, Use, Return, investigates exactly how returnable packaging can be collected at scale.
It evaluates 12 potential return scenarios using six key criteria and provides comparative insight into the two models: kerbside collection and Deposit Return Schemes (DRS) using reverse vending machines.
What is already working?
There are returnable systems already in place that achieve high return rates. For example, Caulibox offers collection points called CauliKiosk, which can automatically recognise and register containers to automate the process.
The Re-Universe system in Blenheim Palace allows users to tap their cup to return it before placing it in the collection container. There are some tech-free solutions that also successfully serve smaller, closed systems, such as New College Oxford’s partnership with FSG Returnables.
These systems achieve return rates over 95% as they are convenient and easy to use. However, different kinds of solutions are required for returnable systems serving the grocery and retail sector, where the supply chain is long and dynamic, and the use and return of the packaging are spaced in time.
Deposit return schemes with reverse vending machines (RVMs)
DRSs have a proven track record in boosting recycling rates. They can be adapted for reuse, using RVMs to register the return of reusable packaging and processing deposit refunds.
For example, existing returnable systems, such as Germany’s reusable PET bottle system, achieve high return rates of over 98%. Collection with RVMs also creates opportunities for tracking each unit for reuse cycles, quality, and cleaning if relevant technology is involved.
The RVM system also benefits from low contamination levels since the packaging remains separated from household waste streams and incorporates a deposit incentive that encourages repeated returns and proper use. However, the challenge is the behaviour shift.
Consumers need not only to rinse and store, but also to return packaging to a designated location. Space to store packaging before return can be limited, with 46% of citizens citing a lack of space at home.
Additionally, 38% mentioned the distance to drop-off points as a challenge. When scaled, the volume of reusable packaging can be considerable; for instance, if 30% of UK plastic packaging were converted to reusable formats, households might need to handle over 22 reusable plastic packaging items per week. Physical returns via RVMs may also conflict with sustainable transportation habits, like walking or cycling.
Use of RVM returns at scale also requires the sacrifice of retail space, which by some estimates might equate to £71m annually.
DRS works well for targeted formats such as bottles or standardised food containers, but could struggle with a more diverse packaging portfolio.
Kerbside collection via local authorities
Kerbside systems are well understood by UK households. They can offer high participation due to minimal behaviour change, enabling reuse at scale.
Consumers are already familiar with the process of rinsing and placing packaging in recycling containers, making participation intuitive for different communities and demographics.
Additionally, local authorities and the waste management sector have the infrastructure that can be adapted to incorporate reusable packaging into existing services. This can potentially reduce the need for major new investments and enable faster implementation.
However, collection rates remain a concern, as even top-performing recycling schemes seldom exceed 65%, potentially too low to sustain economically and environmentally viable reuse systems.
Contamination is another potential issue (depending on the collection mode), as reusable items can become mixed with food waste or non-target materials. This complicates sorting processes and shortens the lifespan of packaging. Traceability can be limited in mixed-stream systems, making it challenging to monitor reuse cycles or support deposit refund mechanisms with the required accuracy.
Kerbside models may be best suited to standardised, durable formats that can tolerate higher contamination risks and are easier to identify with sorting tools, such as AI. Technologies such as digital deposits and smart tagging can improve traceability and engagement.
Transition to reuse
The reuse transition is not simply a question of packaging design; it’s a system design that has to account for all stakeholders, e.g., logistics and consumer experience.
This is recognised by recent Retailers’ collaboration, supported by the Government and WRAP, as they released a statement of intent to promote the circular economy and reduce single-use packaging by developing a shared system for prefill solutions.
Success lies in designing systems that meet people where they are, integrating technology where needed, and ensuring both cost and environmental savings stack up over time. The insights from Buy, Use, Return point to a clear direction: enable reuse to scale not by building entirely new systems, but by reimagining and optimising the ones we already trust.
Download the full report and explore the collection modes in detail at:
recoup.org/research-and-reports/buy-use-return