Borealis and FSG Returnables introduce reusable cup system at UK hospitals

Borealis and FSG Returnables have launched a reusable cup and container system at the Northamptonshire Healthcare NHS Foundation Trust (NHFT) in the UK. The system features Borealis’s Zero Waste Cups made from PP in its Daploy high-melt-strength portfolio using Bockatech’s EcoCore technology. 

According to Borealis, the cups remain reliable after over 1,000 industrial washes and stay stable under heat, detergents, and frequent use. 

Over three years, the system is expected to replace 175,500 disposable cups with 898 reusable ones, saving £27,582 (US$34,201). 

Peter Voortmans, vice president of Marketing Consumer Products at Borealis, says: “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 (US$107 million) to expand our Daploy high-melt-strength PP 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.”

The move also reflects a focus on long-term costs, as the UK’s packaging EPR scheme designates lower fees to reusable and recyclable packaging — known as “green-rated fees.” 

NHFT has introduced reusable food and drink packaging across seven hospital cafes. NHFT previously used compostable packaging, but noted that this generated waste, along with carbon emissions linked to production, transport, and disposal.

Material advantages

 The EcoCore foamed PP structure is ultra-lightweight but is said to provide the strength and thermal performance needed for hot drinks.

Lynn Johnson, managing director at FSG Returnables, says: “We chose to supply the Zero Waste Cup because of its EcoCore technology and material performance.”

“The double-walled, foam-insulated design is lightweight yet extremely durable, making it ideal for high-use reuse systems. Using high-quality PP supplied by Borealis gives us confidence in long-term durability and recyclability.”

Consumer convenience 

Borealis explains that the system was designed to encourage “reuse through simplicity.” Single-use cups and containers have been removed from NHFT cafes, making reuse the only option. 

A short-term token system was installed to help users adjust to the new system, but Borealis says that most chose to keep, wash, and reuse their cups rather than exchange them. 

Joanne Fitzgerald, NHFT deputy general manager, says: “This has been an incredible step forward by NHFT in our journey to protect the planet.” 

“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.”

The program is the first large-scale reusable packaging system within the UK’s National Health Service and is said to be a “visible sign” of the health service achieving its net zero goals. 

“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,” says Borealis.