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Nestlé Professional has created a new material from used coffee grounds and waste plastic, which is being used to make its NESCAFÉ® furniture units. All panels in new units are now made using bespoke materials that combine 70% plastic waste from its Tutbury factory and 30% used Nestlé coffee grounds. 

Developed in partnership with UK-based manufacturer Regency, the new board material, known as the Nestlé Recycled Plastic Coffee Board, replaces older designs made from MDF, plastic and other virgin materials. The boards are solely made from Nestlé waste materials, and they are unique to Nestlé.

This innovation supports the company’s packaging and waste reduction commitments and significantly reduces emissions.

Initially the organisation moved to a UK-sourced unit board material called “Regency Plastic Board” and made from 90% recycled materials, including coffee grounds.

Quantis for Regency conducted a 2018 Life Cycle Assessment which showed that in comparison to the previous Melamine Faced Chipboard (MFC) and MDF panels, these new panels generated 70% less carbon emissions, if used five times.

However, the team wanted to challenge themselves further and had a vision for a closed loop solution that would use Nestlé’s own surplus materials to make the panels.

The new design can be refurbished and reused up to five times, reinforcing a closed-loop approach. To date approximately 200 units of both the 90% and fully recycled panels have been implemented.

Beyond materials, the move has streamlined the supply chain. Five separate distribution stages have been removed, cutting lead times from up to 12 weeks to just 10 days.

Smaller design touches are also getting an update. Condiment holders, once made from plastic, are now crafted using coffee grounds, adding another layer of circular thinking.

This innovation is already sparking interest beyond the UK. Other Nestlé markets are now looking to replicate this initiative, opening the door for greater impact across the global business.

In recognition of this pioneering approach to circular design and emissions reduction, Nestlé Professional was named the winner at both the 2025 Footprint Award in the Waste Prevention and Waste Management category and the Best Closed Loop Project Award at the 2024 waste2zero Awards. These industry accolades highlight the impact and scalability of the NESCAFÉ® self-serve unit project in driving more sustainable practices in foodservice.

Stuart Fleming, Trade Asset Manager UK & Ireland, Nestlé Professional

“I feel we should all be doing what we can to support the environment and sustainability. Despite it not being my role or responsibility, I wanted to see if I could introduce a better solution to house our coffee machines. It’s been fantastic seeing this closed loop solution come to life, where we can now transform our own waste into purpose-built furniture. It’s a very proud moment for our team, business and wider community.”

Julia Jones, head of corporate communications and sustainability, Nestlé Professional

“What I love about this initiative is that the idea came from someone in the business who doesn’t work on sustainability at all. It demonstrates how anyone can drive sustainability action and support our customers on their sustainability journey.”

To learn more about Nestlé Professional’s approach to sustainability and innovation, visit: https://www.nestleprofessional.co.uk/sustainability