Suntory Beverage & Food (SBF) GB&I has revealed a £6.3m ($8.3m) investment focused on revamping the packaging for Lucozade Energy bottles.

This effort aims to significantly cut down on plastic usage while improving the recyclability of the bottles.

The updated design introduces a half sleeve that covers just 50% of the bottle's height, a departure from the previous full-length sleeves.

This change results in a 60% reduction in sleeve weight, equating to a decrease of 956 tonnes (t) of new plastic each year.

Moreover, the redesign is projected to reduce water usage during production, amounting to saving the equivalent of an Olympic-sized swimming pool every 289 days, according to the company.

The project involved the installation of cutting-edge sleeving technology across three production lines at the Coleford, England, facility.

The execution of these modifications took 470 working days and was finalised within a six-week period.

The streamlined sleeve design also improves the recyclability of Lucozade Energy bottles, making it easier for them to be sorted into clear plastics streams at recycling centres.

This initiative is in line with Suntory's sustainability goals and its objectives for reducing emissions, aiding its path towards achieving net zero.

Currently, packaging accounts for 15.5% of the company's scope 3 emissions, and the annual reduction of 956t of plastic supports its aim of a 30% decrease by 2030.

The transformation of Lucozade Energy's packaging follows similar adjustments made to Ribena and Lucozade Sport bottles in prior years.

SBF GB&I supply chain director Karl Ottomar said: “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.

“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.”

Over the last five years, Suntory says it has invested a total of £11.3m in the advancement of sustainable packaging.

The newly designed Lucozade Energy bottles will also showcase an ergonomic embossed design that highlights the brand's distinctive logo.

The revamped bottles are now being introduced in retail outlets throughout the UK.