The Role of Foamed Plastics in Reusable Drinkware

Foamed plastics and renewable polymers drive next-gen sustainable drinkware, which uses less material, improves insulation, and is fully recyclable.

Due to increasing single-use waste, plastic pollution affects every corner of the planet, from mountain peaks to ocean floors. In the UK alone, an estimated 2.5 billion disposable coffee cups are used yearly, with less than 1% recycled. This leads to billions of cups entering landfills annually, placing growing pressure on waste systems and environmental resources.

You can also read: Upcycling Coffee Grounds: A Packaging Alternative.

To address this issue, reusable coffee cups gained popularity, yet their sustainability credentials often remain questionable. Many bamboo cups contain up to 70% melamine, which is non-recyclable and harmful when discarded or incinerated. Stainless steel cups are durable but require up to 50 times more energy during production than other materials. Plastic-based reusables often lack insulation, requiring extra sleeves and materials.

Consumers are now looking for alternatives that reduce impact across material sourcing, manufacturing, use, and end-of-life. FOAMO presents a promising solution, combining performance, safety, and circularity. Developed by First Editions, FOAMO leverages renewable polypropylene and advanced foaming technology to create reusable cups with low carbon footprints.

Improving Reusables with Food Grade Recycled Polymers

FOAMO cups are made from food-grade polypropylene derived from 70% renewable feedstock, including recycled waste cooking oil. This reduces reliance on virgin fossil-based polymers and promotes circular use of industrial and domestic waste. While polypropylene is a plastic, it can offer substantial sustainability advantages when sourced renewably and processed with care.

Compared to standard reusable cups, FOAMO uses 85% less virgin polymer, reducing environmental impact at the material level. The material complies with food safety regulations and is durable under repeated thermal and mechanical stress. FOAMO cups remain fully recyclable through kerbside municipal waste systems. Even the in-mould label (IML) is recycling-compatible, supporting the product’s closed-loop design.

Foaming Technology

FOAMO’s core innovation lies in its post-mould foaming technology, which creates a self-insulating wall structure filled with microscopic air bubbles. This structure significantly improves thermal insulation without increasing material use.

Independent tests show beverages remain at 69°C after ten minutes, eliminating the need for paper sleeves or extra layers. The foamed structure also enables a 50% reduction in plastic usage compared to traditional reusable plastic cups. Each FOAMO cup weighs approximately 60 grams, nearly half the weight of standard UK-made alternatives. This lightweight profile supports user comfort and lower carbon emissions during transportation and distribution.

Lower mass and reduced polymer use mean a lower embodied carbon footprint across each product’s full lifecycle. FOAMO achieves just 0.0372 kilograms of CO₂ equivalent per kilogram, making it one of the lowest in its category. To match FOAMO’s footprint, a typical insulated steel cup would require over 70 more uses for equal impact.

Manufacturing with a Lower Carbon Footprint

FOAMO cups are entirely designed, engineered, and manufactured at Tyseley Energy Park in Birmingham, United Kingdom. The production site is powered by a renewable biomass plant on-site, supporting Birmingham’s 2030 net-zero emissions target.

First Editions uses two IntElect2 all-electric injection moulding machines from Sumitomo (SHI) Demag to ensure energy-efficient production. The 130-ton machine manufactures the cup body with a 12-second cycle time, while a 180-ton machine produces the lids using a four-cavity tool. Both machines run on renewable energy, supporting consistent foaming and minimal material waste.

R&D, Training, and Process Control

Creating the first foam-filled reusable cup with a threaded lid required high-precision moulding and extensive product testing. First Editions invested heavily in research and development to ensure product durability, heat retention, and structural consistency.

Hundreds of cup leak tests were conducted to validate repeatability and reduce potential manufacturing rejects. Precision was essential, as the foam structure influences wall thickness, cup strength, and thermal insulation properties. Sumitomo (SHI) Demag’s IntElect series provided the necessary reactivity, speed, and shot-to-shot consistency during production. Direct-drive injection units ensured exact dosing, which is crucial for achieving uniform foaming and structural performance.

Mark Alderson, Managing Director, completed training in injection moulding and tool setting to strengthen in-house technical capabilities. Hands-on demonstrations helped optimise tool calibration, reduce startup waste, and refine quality control checkpoints. Tool setting precision allowed control over foam density, air bubble distribution, and lid sealing performance.
The result is a stable process with low scrap rates and reliable production cycles, even at high throughput.

Strong internal expertise supported smooth scale-up from pilot runs to full commercial manufacturing for FOAMO cups. The company now maintains control across all variables, from machine configuration to polymer flow behaviour.

Market Launch and Sustainability Messaging

FOAMO officially launched at Merchandise World 2025. Available in seven colours and customisable for branding, the product is sold via the FOAMO website and authorised partners in the UK.

Each cup is dishwasher safe and designed for repeated daily use without compromising performance. The brand message centres on reducing plastic waste without sacrificing function or style. With 70% renewable feedstock and 50% less plastic, FOAMO supports circular economy goals.

It proves that responsibly sourced and engineered plastics can deliver real environmental benefits. FOAMO offers a practical, scalable path toward sustainable drinkware in a low-carbon future.