Finalist interview: Frugal Bottle – Packaging Europe

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As the countdown progresses to the grand unveiling of the 2021 Sustainability Awards winners, we learn more about the Frugalpac Frugal Bottle, which is made from 94% recycled cardboard, and the machine that assembles it.

Congratulations on your selection by the international jury as a finalist for the Sustainability Awards 2021! Could you please present your successful application and how it is innovative?

Thank you. We are very happy to have been nominated for the best machinery for the Sustainability Awards. We have accomplished a lot in the past year and this appointment is the icing on the cake.

Frugalpac is a British sustainable packaging company with a global mission to decarbonize food and drink packaging. We create and supply recycled paper products with the lowest carbon footprint that are easily recycled again.

In June 2020, we launched the Frugal Bottle, the world’s first commercially available paper bottle for wine, spirits and olive oils. The Frugal Bottle was created to help a beverage industry concerned with reducing carbon emissions and attracting a new audience of sustainability-conscious consumers.

The Frugal 75cl bottle is made from 94% recycled cardboard with a food grade pouch. It’s five times lighter than a glass bottle, uses 84% ​​less carbon and offers 360-degree branding for exceptional shelf display.

The Frugal bottle, comparable in cost to a labeled glass bottle, was designed and developed at the Frugalpac Innovation Center in Ipswich.

The business model of Frugalpac is to create and supply Frugal bottle machines for wine producers, co-packers and packaging companies to manufacture the bottles on site, reducing carbon emissions from transporting the bottles in glass to bottling facilities.

Our Frugal Bottle Assembly Machine (FBAM-1) assembles the Frugal Bottle, a 75cl Bordeaux bottle designed for wine, and similar beverages from input components of pre-printed recycled cardboard pieces, from Prefabricated liner pockets, neck labels and water-based adhesives required.

It can produce a nominal number of 630 cylinder units per hour and has been designed to provide continuous operation 24 hours a day x 7 days a week, 49 weeks a year, excluding maintenance needs.

What are the environmental challenges related to packaging that your application addresses, and what impact do you hope it will have?

There are several reasons the Frugal Bottle and FBAM1 help beverage brands looking to be more sustainable.

• It’s lighter. The frugal bottle weighs only 83g, so it’s up to five times lighter than a normal glass bottle, making it easier to carry and lighter to carry.

• It’s better for the environment. An independent life cycle analysis from Intertek found that the frugal bottle, which is made from recycled cardboard without chemicals, has a carbon footprint up to six times (84%) lower than that of a plastic bottle. glass and more than a third less than a bottle made from 100% recycled plastic. The water footprint of the Frugal Bottle is also at least four times smaller than that of glass.

• It’s easy to recycle again. Simply separate the food grade plastic bag from the paper bottle and put them in your respective recycling bins.

• It uses less plastic than a plastic bottle. The frugal bottle uses up to 77% less plastic. Only 15g compared to a 64g bottle made from 100% recycled plastic. The food grade sachet is a laminate of metallized polyester polyethylene, the same material used for bag in box wines. It is recyclable.

• It stands out. As the frugal bottle is made from recycled cardboard, it allows for 360 degree branding on the bottle. No other bottle of wine or spirits looks like it, so it stands out on the shelves and on the table.

• It’s better for wine growers. The Frugal bottle can be produced at the heart of their bottling facility, offers complete freedom of design and printing, is more cost effective to transport while reducing their carbon footprint.

Since its launch in June 2020, Frugalpac has requested to manufacture 90 million Frugal bottles and has called on paper, packaging and co-packaging companies to meet the growing global demand for paper bottles by purchasing their own packaging machine. assembly of Frugal bottles.

Frugalpac currently manufactures Frugal bottles for the Cantina Goccia range of wines, The English Vine and its No1 white wine, Silent Pool Distillers for its Green Man Woodland Gin and the Scottish NB Distillery which launched the first low carbon botanical spirit. AND low in alcohol in a paper bottle called School Night.

We also produce frugal bottles for sake for Japan, olive oil for the Greek company AEONS, Planet B red wine for the Spanish company Bodegas Murviedro and we will launch in the United States soon with a brand of wine. American.

I would love to ask you about the larger picture beyond your successful entry. “Sustainability” in packaging is multidimensional – both in terms of goals and challenges. Could you comment on the most important obstacles that you identify from your position in the value chain, and the types of solutions that you would like to see addressed (e.g. areas of technological innovation, collaboration, of the regulations)?

The main issue we would like to see resolved is the supply of recycled cardboard to the UK.

Right now we have to import some from Germany, but we would like to get all the carton here.

I think we have proven that there is a potentially huge global demand for paper bottles and this is a great opportunity for businesses, from co-packers to paper and packaging printers and manufacturers, to purchase their own frugal bottle assembly machine.

With requests to make 90 million bottles, that’s literally a license to print money!


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