Openreach is launching new fibre modems with 85% recycled plastic casings, aiming to cut 100 tonnes of plastic from its supply chain annually. Part of its “Let’s Reach Zero” strategy, the initiative also includes redesigned packaging, boosting efficiency and sustainability in the rollout of its full fibre broadband network.
Openreach, one of the UK’s largest digital infrastructure providers, is taking a major step toward sustainability by removing 100 tonnes of plastic from its supply chain each year. The move is part of its wider “Let’s Reach Zero” strategy, aimed at achieving net zero carbon emissions in its operations by 2031.
At the heart of this initiative is a redesigned piece of technology known as an Optical Network Terminal (ONT)—a device mounted inside homes to connect customers to Openreach’s full fibre broadband network. These ONTs have been re-engineered with outer casings made from 85% recycled plastic, significantly reducing the use of virgin materials.
The recycled plastics are derived from a variety of sources in the polycarbonate (PC) family, including old laptop and tablet cases, mobile phone housings, and even personal safety equipment. The initiative not only reduces environmental impact but also contributes to the circular economy by giving a second life to previously used plastics.
The Optical Network Terminal (ONT) redesign reflects a sophisticated approach to designing for material reuse:
85% recycled content means less reliance on virgin polycarbonate and petroleum-based plastics.
Sourcing materials from discarded consumer electronics gives new life to waste products, helping keep harmful plastics out of landfill and oceans.
Use of post-consumer recycled polycarbonates supports the emergence of closed-loop supply chains for telecom equipment.
This design evolution moves Openreach closer to eco-design principles being promoted at the EU and UK levels—where product lifecycles are evaluated not just on performance, but on resource efficiency, repairability, and recyclability.
Openreach engineers installed approximately 2 million ONTs last year alone—and that number is set to rise as more customers upgrade to full fibre. With the new designs rolling out this summer, the company estimates it will eliminate the equivalent of eight double-decker buses’ worth of new plastic every year from its manufacturing process and supply chain.
The rollout is supported by a strong network of manufacturing partners, including Nokia, Adtran, Zyxel, and Sercomm. These companies are helping bring the new ONTs to life with sustainability at the forefront.
Openreach has also redesigned the ONT packaging, working in collaboration with Nokia to reduce cardboard usage by 30%. This streamlined packaging allows 40% more devices to fit into each shipping container, improving logistical efficiency and further lowering the carbon footprint of transportation.
According to Abby Chicken, Openreach’s Head of Sustainability, this initiative reflects the company’s dual commitment to building a more reliable, sustainable network and supporting a greener economy.
“Our mission will deliver a more sustainable, reliable network and serve as the digital platform for a greener economy,” she said. “We recognise the environmental impact of building that future, and that’s why we’re committed to using fewer materials and reducing waste.”
With its sights firmly set on net zero emissions by 2031, Openreach is showing how sustainable design can be scaled in one of the UK’s most vital infrastructure sectors. By working across its supply chain to rethink materials and packaging, the company is proving that green innovations can also drive operational efficiency.
As the telecoms industry continues to modernise, Openreach’s recycled ONTs and plastic-reduction strategy may well set a benchmark for sustainable infrastructure worldwide.
Telecommunications accounts for an estimated 2-3% of global carbon emissions, largely due to energy-intensive networks and manufacturing processes. While energy efficiency in data centres often gets the spotlight, equipment materials and packaging are fast becoming critical areas of climate action.
Openreach’s initiative could:
Pressure other telecom operators to examine the full life cycle of their devices and components.
Encourage policy alignment with future UK and EU directives on product environmental footprinting and extended producer responsibility.
Serve as a case study for regulators, showing how sustainability and performance need not be mutually exclusive.
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