Three Gold awards and a Silver saw RePlay top the trophy tally at this year's Australasian Packaging Innovation & Design Awards (PIDA). But behind the accolades lies an equally important story: the practical challenges of making reusable packaging systems commercially viable.
Bonson Packaging's RePlay Returnable System emerged as the standout project at the 2026 PIDA Awards, taking home Gold in Sustainable Packaging Design (Reuse), Marketing Design and Labelling & Decoration Design, along with Silver in Food Packaging Design.
The awards recognise what judges saw as an ambitious attempt to rethink not just a package, but the packaging system itself.
Rather than redesigning a single-use pack, RePlay combines reusable packaging, digital tracking technology, retail operations, washing infrastructure, logistics and consumer participation into a supermarket-based return system.
Speaking to PKN following the awards, Bonson Packaging CEO David Tsui said what distinguished RePlay was its focus on redesigning the entire packaging system rather than developing another packaging format.
“Most packaging innovations improve a single-use package, whereas RePlay set out to test whether a reusable packaging model could work within a mainstream supermarket environment.”
According to Bonson, the trial has demonstrated that a returnable packaging system can operate within a mainstream supermarket environment, supported by the necessary infrastructure, technology and partnerships. The more difficult challenge now is proving long-term commercial viability.
Consumer behaviour remains the biggest hurdle
Perhaps the most significant finding to emerge from the project is that the primary challenge is neither the packaging nor the supporting technology, but consumer behaviour.
Tsui said the trial had reinforced a lesson emerging from reuse initiatives around the world.
“The biggest challenge has not been the packaging or the technology. It has been changing consumer behaviour.
“The current food packaging system is incredibly convenient, and consumers are accustomed to single-use packaging that requires no further action.
“Like many reuse initiatives around the world, we have learned that convenience is ultimately the most important driver of customer behaviour.”
The New Zealand supermarket trial is currently achieving return rates of around 80 per cent. While encouraging, Bonson says this remains well below the level needed for reuse systems to reach their commercial and environmental potential.
According to the company, the findings reflect a challenge common to reuse initiatives globally. Consumers generally support reusable packaging in principle, but participation falls when extra effort is required.
Even with tap-to-borrow technology and convenient return points, shoppers must remember to return containers and actively choose the system each time they shop.
“The reality is that people generally prefer convenience and are resistant to changes in established habits," Tsui said.
“One of the most important lessons from the trial is that even small additional actions can have a significant impact on participation rates."
Commercial viability remains elusive
Tsui was equally candid about the commercial realities: “At this stage, we would not say RePlay is commercially workable at scale.
“The purpose of the trial is to understand what would be required to make a reusable packaging system commercially viable.”
According to Bonson, significantly higher participation rates and greater operating scale will be needed before reuse systems become commercially sustainable.
The company believes mainstream adoption will depend on making participation easier and more rewarding for consumers, or on policy measures that make single-use packaging comparatively less attractive through pricing signals, regulation or other incentives.
While RePlay has yet to demonstrate commercial viability, Bonson says the trial has generated valuable insights into consumer behaviour, operational requirements and the infrastructure needed to support reuse in a supermarket environment.
Recognition for tackling a difficult challenge
Tsui said winning three Gold awards and a Silver was recognition of the commitment shown by everyone involved in developing the RePlay system.
“It is is an outstanding achievement and one that everyone involved with the RePlay Returnable System should be immensely proud of.
“The RePlay Returnable System demonstrates what is possible when organisations come together with a shared purpose to create practical, sustainable change.”
While celebrating the recognition, Tsui said the project's greatest value may lie in the insights it is generating for the future of reuse systems.
“This is just the beginning of the RePlay Return story, and I look forward to seeing the programme continue to grow, welcome new partners, reach more communities and make an even greater contribution to New Zealand's circular economy.”
Project partners
The RePlay Returnable System was developed through a collaboration involving Bonson Packaging, Foodstuffs North Island, New World Birkenhead, Willis Street Metro, Circularity, Again Again, New Zealand's Ministry for Cities, Environment, Regions and Transport, Anew, Charopy Smart Bins, MCC Global IML, Blender and Hula.
