Amcor has developed engineered refillable packaging containers for Ocado Retail’s expanding online grocery reuse system in the UK, with the project highlighting how packaging is being redesigned for repeated circulation rather than single-use consumption.
Unlike conventional refill concepts focused mainly on sustainability messaging, the innovation in this project lies in the structural and operational engineering of the packaging itself. The containers were specifically designed to survive repeated industrial filling, e-commerce handling, consumer use, collection, hot washing and refilling cycles while maintaining hygiene, durability and logistics efficiency.
Amcor developed two different formats: a 2 kg container with a wide-mouth opening for dry products such as pasta and rice, and a 3 kg version with a narrower neck for liquid products including detergents and household cleaners.
A key packaging innovation is the elimination of “trap points” within the container geometry. Rounded internal transitions and softened shoulder areas were engineered to prevent food residue or rinse water from collecting during industrial washing operations. The packs also combine square-base structures for improved space efficiency in Ocado’s delivery crates with ergonomic integrated handles for repeated handling throughout the supply chain.
The material structure and wall thickness were also redesigned to withstand repeated hot-wash cycles without weakening or compromising food-contact safety. According to project estimates, each container could potentially complete between 50 and 100 refill cycles before removal from circulation.
The project is increasingly being viewed within the packaging industry as an example of how reusable packaging systems may require not only new materials, but entirely new approaches to packaging design, reverse logistics, hygiene engineering and retail infrastructure integration.