Nestlé Lightweight Bottling Plant, Buxton, Derbyshire, United Kingdom
Nestlé Waters UK started production at its new water bottling and warehouse facility at Waterswallows in Buxton, in the UK, in May 2012. The new Derbyshire-based facility is hailed as one of the most innovative and efficient bottling facilities in Europe. Nestlé announced its plans to construct the facility in November 2011.
The planning application for the construction of the bottling facility was submitted by Cass Associates on behalf of Nestlé Waters. Nestlé Waters invested more than £35m in the bottling facility and warehouse.
Details of Nestlé Waters' new bottling facility
The new factory is Nestlé Waters UK's first bottling facility to include warehousing capabilities. The building features a wave-like roof and has a footprint of approximately 23,000 square metres.
The Derbyshire dry stone walls are built to re-establish field patterns and set site boundaries. A 3.5km-long pipeline supplies the mineral water from the source under the Crescent building to the new facility.
The new facility uses the heat generated by the bottling lines to warm up the warehouse and office areas. It is equipped with a sustainable drainage system to handle the water running from the site.
With the innovative solutions incorporated by the facility to reduce the environmental impact, the company is hopeful to achieve the BREEAM (BRE environmental assessment method) 'Excellent' rating for the plant.
Measures have also been taken to cut-down the operational costs and improve the transport infrastructure and ecology of the site.
Bottling lines at Nestlé Waters UK's Buxton plant
The new bottling lines will manufacture the lightest weight water bottles in the UK. The U-shaped production lines are designed to significantly reduce the total energy output of the site. The innovative new bottle design consumes 25% less PET plastic on average when compared to the existing design. The bottles are fully recyclable.
The output from the plant 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 lighter bottles feature a smaller neck and an ergonomic shape that requires less plastic. The bottle fits comfortably in the hand. The bottling line is 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 manufacturing. The company also plans to certify the facility as zero waste to landfill.
Marketing commentary for Nestlé Water UK
Nestlé Waters UK has witnessed double digit growth for its bottled water brands during recent years. It is the only bottled water manufacturing company whose market share had grown for three successive years (2008 - 2011) despite the recent global economic downturn.
Buxton Natural Mineral Water is the number one mineral water brand in Britain. Nestle Pure Life, which was launched in 2008, achieved a market share of 4.5% by 2011.
With these two established brands, the new light weight bottling factory in Buxton will further complement Nestlé Waters UK's market leading portfolio of bottled water products.
Nestlé, in July 2009, opened its new contract-packing facility in York, UK.
In February 2005, Nestlé began installation of an RFID-augmented automated pallet labelling system.