Zero Co's big refill rethink
A major system overhaul will help the circular economy startup dispense with plastic.
Circular economy startup Zero Co is rolling out a brand new paper-based refill system to drastically reduce plastic in its consumer product packaging.
The company has spent two years developing its new system, called ForeverFill, which revamps its entire personal care and cleaning range.
ForeverFill is a paper-based system that will work alongside reusable Forever Bottles that are made from 90% recycled materials. Available in three colours, they are designed to be durable and guaranteed for life.
The new packaging design cuts plastic usage by up to 97% compared to its traditional formats like bottles and pouches, according to Zero Co. Additionally, the new system is expected to lower freight emissions by up to 75%.
"Over time, we’ve come to realise that it’s not the perfect solution, and there’s a better way."
The shift to ForeverFill marks a big departure from Zero Co’s previous closed-loop system which relied on customers returning reusable plastic pouches.
The company says this approach generated high carbon emissions from shipping and cleaning and was inconvenient for consumers. Only 42% of pouches were ever returned with the remainder becoming single-use plastic.
“When we launched Zero Co, we believed a closed-loop system was the best way to tackle the single-use plastic problem,” the company said.
“But over time, we’ve come to realise that it’s not the perfect solution, and there’s a better way.”
Curbside approach
ForeverFill, in contrast, will simplify the process for consumers by allowing refills to be recycled at the curbside.
The transition will also see some products reformulated into dissolvable tablets and raw powders to further reduce costs and plastic waste, Zero Co says.
The company has also committed to a "10-for-1" promise, where for every product sold, the equivalent of 10 plastic water bottles will be removed from oceans, rivers, and beaches globally.
This initiative builds on Zero Co's previous efforts which have reportedly resulted in the removal of over 32 million water bottles' worth of waste.
Zero Co said it will support current customers during the transition. The company has pledged to take back all old bottles and pouches and these will either be turned into new Zero Co products or will be responsibly recycled. Current customers, meanwhile, will receive free replacement Forever Bottles to kickstart their transition to the new ForeverFill system.
