Nestlé Lightweight Bottling Plant, Buxton, UK, United Kingdom

Nestlé Waters UK unveiled a new water bottling and warehouse facility at Waterswallows in Buxton, UK, in November 2011. Buxton is a town in the county of Derbyshire. The new facility is a result of many years of research and development by the company.

It is expected be one of the most innovative and efficient bottling facilities in Europe when fully operational in Spring 2012.

The planning application for the construction of the bottling facility was submitted by Cass Associates on behalf of Nestlé Waters. Nestlé Waters is investing more than £35m in the bottling facility and warehouse.

Design and construction of Nestlé Waters' new water bottling facility

The new factory will be the first bottling facility of Nestlé Waters UK to have warehousing capability. The building will feature a wave-like roof and have a footprint of approximately 23,000m2.

The Derbyshire dry stone walls will be built to re-establish field patterns and set site boundaries. A 3.5km long pipeline will supply the mineral water from the source under the Crescent building to the new facility.

The new site will consider the provisions for using the heat generated by the bottling lines. The generated heat will be eventually utilised to warm up the warehouse and office areas. The facility will be provided with a sustainable drainage system to handle the water running from the site.

The company is working to achieve the BREEAM (BRE environmental assessment method) 'Excellent' rating for the plant. The certification evaluates the innovative solutions used to reduce the environmental impact of the building.

It also assesses the measures to cut-down the operational costs and improve the transport infrastructure and ecology of the site.

Bottling lines installed at Nestlé Waters UK's Buxton complex

The new bottling lines will manufacture the lightest weight water bottles in the UK. The lines are designed to significantly reduce the total energy output of the site. The innovative new bottle design will consume 25% less PET plastic on an average when compared to the existing design. The bottles will be fully recyclable.

The output will be used for the entire still range of Buxton Natural Mineral Water, which is available in 25cl (250ml), 50cl (500ml), 75cl (750ml) and one litre sizes, and Nestlé Pure Life which is available in 33cl (330ml) and 50cl (500ml) formats.

The new environmental certification of Buxton and Nestlé Pure Life bottles will be shown off using the refreshed packaging to highlight the changes.

The lighter bottles will feature a smaller neck and an ergonomic shape that requires less plastic. The bottle will fit comfortably in the hand. The bottling line will be complemented by the new sports cap launched by the Nestlé Waters UK.

The cap includes a tamper evident seal that remains with the lid when opened. The new sports cap will be available on the Buxton Natural Mineral Water 25cl (250ml), 75cl (750ml) and one litre bottles and the Nestlé Pure Life 33cl (330ml) formats.

The new bottling unit and warehouse facility will enable Nestlé Waters to reduce the total quantity of water consumed in the manufacturing. The company also plans to certify the facility as zero waste to landfill by the end of 2012.

Marketing commentary for Nestlé Water UK and its bottled water brands

Nestlé Waters UK has witnessed double digit growth for its bottled water brands over the last three years (2008-2011). It is the only bottled water manufacturing company whose market share has grown for three successive years despite the recent global economic downturn.

Buxton Natural Mineral Water is the number one mineral water brand in Britain. Nestle Pure Life has achieved a market share of 4.5% by 2011.

It was launched in 2008. It is also the biggest brand within the entire 500ml grocery market. Nestlé Waters expects the new bottling factory in Buxton will further complement its market leading portfolio of bottled water.