Frugalpac sells first paper bottle machine as rising glass costs boost interest in renewables

16 Jun 2022 --- Frugalpac has sold the “world’s first” paper bottle machine, which produces the Frugal bottle – the “first and only” commercially available wine, spirits and olive oil bottle made from recycled paper. 

The UK-based company secured the first customer for its Frugal bottle machine branded FBAM-1 in Canadian packaging firm KinsBrae Packaging. The machine can produce more than two and a half million Frugal bottles a year.

“The Frugal bottle is made from a paperboard shell which is 94% recycled paper and a food grade pouch inside to hold the liquid,” Malcom Waugh, CEO at Frugalpac, tells PackagingInsights.

“Our aim is to establish Frugal bottle production hubs around the world so we can reduce the carbon even further by reducing transportation costs and carbon miles. We will also offer our customers the lowest possible cost for the Frugal bottle.”

The Frugal bottle consists of a 94% recycled paper shell and food grade pouch.Cost considerations
The move comes as Europe struggles with a shortage of beer bottles amid rising production costs and a lack of lorry drivers. The German Brewers’ Association recently warned there could be a shortage of glass bottles this summer.

“With the rising cost of glass production due to increased fossil fuel costs to make glass bottles, we are close to parity on the cost of our paper bottles against glass,” adds Waugh.

“If one invested in a Frugal bottle assembly machine, they would be at parity or below.”

Inquiries gain traction
Frugalpac says it has also received strong inquiries from 87 other international brands, contract packing and packaging companies interested in buying Frugal bottle assembly machines in the next few months. 

It is calling on other firms to help it pioneer the “paper bottle revolution” by investing in its Frugal bottle machines.

Canada is already selling wine in the Frugal bottle through its LCBO stores across Ontario. 

Waugh had announced the deal at the London Wine Fair, one of the largest wine fairs in the world – two years after launching the first Frugal bottle in June 2020 with Cantina Goccia’s 3Q wine in the UK.

Frugalpac is calling on other businesses to help them drive the “paper bottle revolution.”Frugalpac versus plastic bottles
An independent Life Cycle Analysis (LCA) carried out by Intertek tested the Frugal bottle against bottles made from glass and PET plastic, finding:

• The Frugal bottle has the lowest carbon footprint with 91.9 g CO2e – 84% lower than a 440 g imported glass bottle (558.2 g CO2e) and 34% lower than a bottle made from 100% recycled plastic (138.6 g CO2e).
• The Frugal bottle’s carbon footprint was four times less than a 345 g lightweight glass bottle made in the UK (382 g CO2e).
• The Frugal bottle uses up to 77% less plastic than a plastic bottle. It has only 15 g against a 64 g wine bottle made from 100% recycled plastic.
• The Frugal bottle’s water footprint is at least four times lower than a glass bottle. It takes 2.5 L of water to make a lightweight 345 g glass bottle made in the UK but only 0.6 L to make a Frugal Bottle.

“The LCA looked at the ‘cradle to grave’ life cycle of all bottles, including mineral extraction, manufacture, transportation, distribution, filling and recycling or incineration,” notes Waugh.

Paper-based alternatives 
Fiber-based packaging is creating opportunities for brands and retailers to switch from fossil fuel-based rigid and flexible plastic packaging formats to renewable alternatives. 

Earlier this year, we discussed fiber-based packaging trends with Daniel Frey, head of innovation at Huhtamaki Fiber Foodservice Europe-Asia-Oceania, and Will Mercer, R&D director for the Paper Business Unit at Coveris.

According to Innova Market Insights, a majority of global consumers perceive paper-based packaging as being “somewhat environmentally sustainable” (37%) or “very environmentally sustainable” (35%). Meanwhile, 31% of consumers perceive plastic packaging as “somewhat environmentally sustainable” and 15% as “very environmentally sustainable”.

An LCA found the Frugal bottle has a lower carbon footprint than glass and plastic bottles.“Now we’re asking other packaging companies, bottlers and co-packers to join our paper bottle revolution by investing in their own Frugal bottle machines,” says Waugh.

“It is clear consumers are keen on more [environmentally] sustainable forms of packaging and this is a great opportunity for packaging companies, bottlers and the print industry.”

Commercialization no concern
Different drinks producers from around the world have launched wines, spirits and olive oils in the Frugal bottle.

“We don’t see major commercial challenges,” says Waugh. “Since launching two years ago, we have made over 1 million Frugal bottles and 25 drinks brands around the world are using it. We also have inquiries to make over 120 million bottles.”

In related news, Kraft Heinz partnered with Pulpex to develop a paper-based, renewable and recyclable bottle made entirely from responsibly sourced wood pulp. Starting with its ketchup bottle, Heinz is “the first sauce brand” to test the potential of Pulpex’s paper bottle.

Also, Paboco revealed a new advanced paper closure, described as a “groundbreaking development,” in collaboration with Blue Ocean Closures. The paper closure moves Paboco closer to its target of developing a recyclable and fully bio-based paper bottle ready for the market by 2023. 

By Natalie Schwertheim