ReLoop has introduced a circular packaging model that combines ready-made meals with the automatic return of reusable and traceable containers. The project aims to reduce the environmental impact of single-use plastic packaging by up to 95%, using containers designed to withstand at least 40 reuse cycles while maintaining food safety, functionality and consumer acceptance.

The initiative brings together AUSOLAN, AWAYTER, ITC Packaging and AIMPLAS, the Plastics Technology Centre. Together, the partners are developing a closed-loop system for prepared food that integrates dispensing, return, cleaning, traceability and reuse in one model. The goal is to move beyond recycling and create a practical reuse system that can operate in real catering environments.

The project responds to a major packaging challenge: single-use plastic remains deeply embedded in foodservice and prepared meal distribution. According to the United Nations Environment Programme, more than 400 million tonnes of plastic are produced worldwide each year, and around half is designed for single use. With less than 10% of plastic waste recycled globally, reuse systems are increasingly being explored as a more structural solution.

ReLoop shows that reusable food packaging requires more than a durable container. It needs traceability, logistics, cleaning protocols and consumer-friendly return infrastructure.

One of the most important elements of the project is the development of reusable food packaging that can be tracked throughout its lifespan. Each container must remain safe for food contact, withstand repeated washing and drying, retain its appearance and be recyclable at the end of its useful life. This makes material selection critical, because the packaging must tolerate mechanical stress, cleaning cycles and repeated handling.

Traceability is another central feature. ReLoop is investigating systems that monitor the journey of each container, record the number of uses and support automated return management. This data is essential for proving whether reuse is working in practice. Without reliable tracking, it becomes difficult to measure loss rates, calculate environmental benefits or manage container circulation efficiently.

• Reusable containers are being designed for at least 40 use cycles.
• Traceability will allow each package to be monitored throughout the system.
• Automatic return is intended to make reuse easier for users and operators.
• Cleaning and drying protocols are being developed to protect food safety.

The project also includes a 24/7 digital canteen concept. Users will be able to reserve prepared meals, make contactless payments and return the container through an automated system. After return, the container will be collected, sanitised and placed back into circulation. This integrated model is designed to close the loop between food delivery, packaging recovery and reuse.

Food safety is one of the most sensitive parts of the project. Reusable packaging for prepared meals must be cleaned and dried correctly before each new use. Inadequate drying can increase microbial risk, while overly aggressive cleaning may damage the material and shorten its lifespan. ReLoop is therefore studying specific washing and drying protocols suited to the containers and the foods they carry.

The regulatory context is also pushing the market toward reuse. In Spain, Law 7/2022 applies a tax of €0.45 per kilogram on non-recycled plastic used in non-reusable packaging. This type of measure increases pressure on companies to find alternatives that reduce single-use plastic without damaging competitiveness or operational efficiency.

For institutional catering, workplaces, schools, hospitals and communal dining environments, closed-loop reuse may be especially relevant. These settings often have controlled distribution points, predictable user flows and centralised cleaning possibilities, which can make reusable packaging easier to manage than in fully open retail systems.

The ReLoop project highlights the next stage of sustainable packaging innovation: system design. A reusable container alone is not enough. To compete with disposable packaging, reuse must be convenient, hygienic, measurable and economically viable. That requires collaboration between foodservice operators, technology providers, packaging manufacturers and research centres.

If successful, ReLoop could provide a replicable model for prepared meals and other controlled foodservice environments. By combining durable packaging, automated return, digital tracking and validated sanitation, the project points toward a future where reuse becomes a managed packaging service rather than a consumer burden.