Lucozade producer Suntory Beverage & Food (SBF) GB&I has invested £6.3 million in a major packaging redesign for Lucozade Energy bottles, significantly reducing plastic use and supporting the efficient recycling of its bottles.
Lucozade Energy bottles will now feature a half sleeve that covers just 50 per cent of the bottle height compared to previous full-length sleeves. SBF said this would lead to a 60 per cent reduction in total sleeve weight, removing 956 tonnes of new plastic per year. The changes also reduce water use during production, equivalent to an Olympic-sized swimming pool every 289 days.
The project involved installing new sleevers with the latest technology across three different production lines in SBF GB&I’s factory in Coleford. The work took a collective 470 working days, delivered in only six weeks.
“As one of the biggest energy brands in the UK, producing over 3,000 bottles of Lucozade Energy per minute, this has been a complex and large-scale change for our factory,” Karl Ottomar, supply chain director, SBF GB&I, commented.
“While reducing a drink’s sleeve size may sound simple, it has required a full redesign of the bottle and complete change in componentry on our production lines. The team have dedicated thousands of hours to plan and then successfully implement the changes on our lines and I’m so proud of their incredible commitment to this project and helping us meet our sustainability goals.”
Fraser McIntosh, Head of external affairs and sustainability, SBF GB&I, said the change marks a “significant step forward” in the company’s journey towards achieving 100 per cent sustainable plastic packaging across its portfolio by 2030.
“At a time when we face increasing cost pressures as a business, we continue to prioritise sustainability, demonstrating our company value of Growing for Good. It’s another major investment in our factory, helping to build a sustainable future for our brands,” McIntosh added.
The changes are also important for the recyclability of Lucozade Energy bottles as the reduced sleeve continues to support bottle to bottle recycling. It ensures the bottle can be sorted into the clear plastics stream at recycling facilities allowing it to be recovered to create new bottles again.
The packaging evolution for Lucozade Energy follows similar changes to the sleeve length made to Ribena bottles in 2020 and Lucozade Sport in 2021. SBF GB&I has invested a total of £11.3m over five years to support the development of its sustainable packaging as it collaborates with industry to achieve a circular economy for plastics, work that includes advocating for and delivering a deposit return scheme in the UK by October 2027.
The new Lucozade Energy bottles will also feature a new ergonomic embossed design showcasing Lucozade’s iconic ‘Arc’ logo, enhancing both brand recognition and bottle texture. The new bottles are now rolling out in store.
