Frugalpac has introduced a faster production system for its paper Frugal Bottles, increasing manufacturing capacity for drinks companies, fillers and packaging partners seeking alternatives to glass.
The new Frugal Bottle Assembly Machine 2 (FBAM-2) can produce 14 million paper bottles a year.
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That is more than five times the annual capacity of the earlier FBAM-1 system, which can manufacture up to 2.5 million units.
The machine is intended for use at bottling plants and packaging sites in different markets.
Frugalpac said this setup allows bottles to be made nearer to filling lines, intending to reduce cost, carbon output and supply chain risk.
The system also includes multi-lane configurations for both lower-volume and larger-scale production.
The UK-based company launched the Frugal Bottle in 2020.
The bottle is made from 100% recycled paperboard and, according to Frugalpac, has a carbon footprint up to 84% lower than that of a standard glass bottle.
The company said the new machine cuts the cost of the Frugal Bottle by as much as 30% compared with existing paper bottles, bringing it into line with, or below, the cost of a labelled glass bottle.
Since the product was introduced in 2020, more than four million Frugal Bottles have been made.
The bottle is already sold through retailers including Sainsbury’s, Aldi, Whole Foods, Target and 7-Eleven.
The company added that FBAM-2 supports distributed manufacturing, enabling partners such as Monterey Wine Company in the US and KinsBrae Packaging in Canada to assemble bottles at their own facilities.
Frugalpac CEO Malcolm Waugh said: “For decades, glass has been the default for wine and spirits. But it’s heavy, energy-intensive and increasingly expensive to use and recycle.
“What’s changed is that packaging is no longer just a design choice; it’s a climate decision. Glass is no longer neutral.
“The FBAM-2 gives the industry a practical way to move faster, cutting carbon, reducing costs and producing bottles closer to where drinks are made and sold.
“The opportunity is clear. The technology is ready. The future of packaging is lighter and of a lower cost, and the industry now has the tools to get there.”
