{"id":21942,"date":"2026-04-10T15:26:22","date_gmt":"2026-04-10T15:26:22","guid":{"rendered":"https:\/\/cpmirror.com\/?p=21942"},"modified":"2026-04-10T15:26:23","modified_gmt":"2026-04-10T15:26:23","slug":"frugalpac-launches-high-speed-paper-bottle-machine-to-meet-surging-global-demand","status":"publish","type":"post","link":"https:\/\/cpmirror.com\/index.php\/2026\/04\/10\/frugalpac-launches-high-speed-paper-bottle-machine-to-meet-surging-global-demand\/","title":{"rendered":"Frugalpac launches high-speed paper bottle machine to meet surging global demand"},"content":{"rendered":"\n<p>British sustainable packaging company Frugalpac has today unveiled a&nbsp;<strong>high-speed new machine<\/strong>&nbsp;that dramatically increases the production of its paper Frugal Bottles, enabling drinks brands, fillers and packaging partners to scale beyond the limits of glass.<\/p>\n\n\n\n<p>The launch comes as the UN\u2019s World Meteorological Organization recently warned that the Earth\u2019s climate is increasingly out of balance, with greenhouse gas emissions driving accelerating warming.<a href=\"https:\/\/spnews.com\/frugalpac-launches-high-speed-paper-bottle-machine-to-meet-s\/#x__ftn1\">[1]<\/a><\/p>\n\n\n\n<p>The new&nbsp;<strong>Frugal Bottle Assembly Machine 2 (FBAM-2)<\/strong>&nbsp;is a scalable platform capable of producing&nbsp;<strong>14 million paper bottles a year&nbsp;<\/strong>&#8211; more than five times the capacity of its predecessor, FBAM-1, which produces up to 2.5 million annually<a href=\"https:\/\/spnews.com\/frugalpac-launches-high-speed-paper-bottle-machine-to-meet-s\/#x__ftn2\">[2]<\/a>.<\/p>\n\n\n\n<p>Designed for installation at bottling plants and packaging facilities worldwide, the FBAM-2 allows partners to manufacture Frugal Bottles at scale, closer to filling lines, reducing cost, carbon and supply chain risk. Its flexible multi-lane options allow for both smaller and significantly larger production volumes.<\/p>\n\n\n\n<p>Frugalpac, a King\u2019s Award-winning cleantech company based in Suffolk, launched the&nbsp;<strong>Frugal Bottle<\/strong>&nbsp;in 2020. Still the world\u2019s first and only commercially available paper bottle for wines, spirits and edible oils. It is made from 100% recycled paperboard and has a carbon footprint up to 84% lower than a standard glass bottle.<\/p>\n\n\n\n<p><strong>Driving Costs Down<\/strong><\/p>\n\n\n\n<p>With the FBAM-2, the Frugal Bottle is now up to 30% lower cost than the current paper bottles, bringing it to price parity &#8211; or better &#8211; than a labelled glass bottle. As energy prices are increasing at pace, the Frugal Bottle is not just the sustainable choice but the smart economic one.<\/p>\n\n\n\n<p><strong>Scaling beyond glass<\/strong><\/p>\n\n\n\n<p>The launch of FBAM-2 marks a step change for the drinks industry, where demand for lower-carbon packaging is accelerating but production capacity has remained a bottleneck.<\/p>\n\n\n\n<p>Until now, the rollout of paper bottles has been limited by manufacturing scale. FBAM-2 removes that constraint, enabling millions more bottles to be produced annually at a single site.<\/p>\n\n\n\n<p>This opens the door for:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Large-scale brand adoption<\/li>\n\n\n\n<li>Multi-market rollouts<\/li>\n\n\n\n<li>Integration into existing bottling operations<\/li>\n<\/ul>\n\n\n\n<p><strong>Industry under pressure<\/strong><\/p>\n\n\n\n<p>The launch comes as the global drinks sector faces mounting pressure from multiple directions.<\/p>\n\n\n\n<p>Glass production requires furnaces operating at temperatures of around&nbsp;<strong>1,500\u00b0C<\/strong>, often powered by fossil fuels, and supply chains have been hit in recent years by energy shocks, rising costs and material shortages.<\/p>\n\n\n\n<p>At the same time, new&nbsp;<strong>Extended Producer Responsibility (EPR)&nbsp;<\/strong>rules across the UK, Europe and other markets mean companies are increasingly charged for the environmental cost of their packaging, with heavier materials like glass among the most expensive.<\/p>\n\n\n\n<p>Retailers are also turning their attention to packaging as a major source of emissions. Alcoholic drinks are now the&nbsp;<strong>largest contributor to supermarket packaging impact<\/strong>, accounting for roughly&nbsp;<strong>33%<\/strong>&nbsp;of all environmental impacts in the grocery aisle, driven largely by glass bottles.<\/p>\n\n\n\n<p><strong>Each Frugal Bottle saves 348g of CO<\/strong><strong>\u2082<\/strong><strong>e<\/strong>&nbsp;compared to a glass bottle. With&nbsp;<strong>4 million bottles already produced<\/strong>, the cumulative savings are now over&nbsp;<strong>1,392 tonnes of CO<\/strong><strong>\u2082<\/strong>&nbsp;&#8211; the equivalent of 3.5 million miles driven in a petrol car.<\/p>\n\n\n\n<p><strong>A Category Under Strain<\/strong><\/p>\n\n\n\n<p>Furthermore, a&nbsp;<strong>2023 Shorr Packaging study<\/strong>&nbsp;revealed that&nbsp;<strong>73% of consumers<\/strong>&nbsp;are willing to switch brands for more sustainable packaging. Younger cohorts Gen Z and Millennials are leading this shift, increasingly viewing heavy glass as a symbol of climate inertia rather than a mark of quality.<\/p>\n\n\n\n<p>Packaging is becoming one of the most visible ways for brands to demonstrate climate action and lighter, recyclable formats such as paper are gaining trust and traction.<\/p>\n\n\n\n<p>With full 360-degree printability, the Frugal Bottle gives brand owners a powerful canvas to engage a new generation of discerning consumers with products that mean something to this generation<\/p>\n\n\n\n<p><strong>The Future is Lighter<\/strong><\/p>\n\n\n\n<p>Since its 2020 debut, over&nbsp;<strong>4 million Frugal Bottles<\/strong>&nbsp;have been produced. The format is already a retail reality, stocked by giants such as&nbsp;<strong>Sainsbury\u2019s, Aldi, Whole Foods, Target, and 7-Eleven<\/strong>.<\/p>\n\n\n\n<p>The company\u2019s approach combines&nbsp;<strong>low-carbon materials<\/strong>&nbsp;with&nbsp;<strong>localised production<\/strong>, allowing bottles to be assembled closer to filling sites, reducing transport emissions, breakage and supply chain risk.<\/p>\n\n\n\n<p>The FBAM-2 enables distributed manufacturing, allowing early-adopter partners like&nbsp;<strong>Monterey Wine Company (USA)<\/strong>&nbsp;and&nbsp;<strong>KinsBrae Packaging (Canada)<\/strong>&nbsp;to assemble bottles on-site. This eliminates packaging miles &#8211; the carbon cost of shipping empty glass bottles &#8211; and secures the supply chain against global glass shortages.<\/p>\n\n\n\n<p><strong>J.P. Grogan, Product Director at Frugalpac, said:&nbsp;<\/strong>\u201cThe FBAM-2 is the industrial rollout the mass market has been waiting for.<\/p>\n\n\n\n<p>\u201cWe have engineered it for maximum uptime and modular flexibility, allowing it to handle everything from spirits and wine to oils and ready-to-drink (RTD) cocktails.<\/p>\n\n\n\n<p>\u201cThe technology is ready; the era of heavy glass is over.\u201d<\/p>\n\n\n\n<p><strong>Malcolm Waugh, CEO of Frugalpac, added:&nbsp;<\/strong>\u201cFor decades, glass has been the default for wine and spirits. But it\u2019s heavy, energy-intensive and increasingly expensive to use and recycle.<\/p>\n\n\n\n<p>\u201cWhat\u2019s changed is that packaging is no longer just a design choice, it\u2019s a climate decision. Glass is no longer neutral.<\/p>\n\n\n\n<p>\u201cThe 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.<\/p>\n\n\n\n<p>\u201cThe 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.\u201d<\/p>\n","protected":false},"excerpt":{"rendered":"<p>British sustainable packaging company Frugalpac has today unveiled a&nbsp;high-speed new machine&nbsp;that dramatically increases the production of its paper Frugal Bottles, enabling drinks brands, fillers and packaging partners to scale beyond the limits of glass. The launch comes as the UN\u2019s World Meteorological Organization recently warned that the Earth\u2019s climate is increasingly out of balance, with<\/p>\n","protected":false},"author":1,"featured_media":21943,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[66],"tags":[916,51],"class_list":{"0":"post-21942","1":"post","2":"type-post","3":"status-publish","4":"format-standard","5":"has-post-thumbnail","7":"category-products","8":"tag-frugalpac","9":"tag-top-news"},"_links":{"self":[{"href":"https:\/\/cpmirror.com\/index.php\/wp-json\/wp\/v2\/posts\/21942","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/cpmirror.com\/index.php\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/cpmirror.com\/index.php\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/cpmirror.com\/index.php\/wp-json\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/cpmirror.com\/index.php\/wp-json\/wp\/v2\/comments?post=21942"}],"version-history":[{"count":1,"href":"https:\/\/cpmirror.com\/index.php\/wp-json\/wp\/v2\/posts\/21942\/revisions"}],"predecessor-version":[{"id":21944,"href":"https:\/\/cpmirror.com\/index.php\/wp-json\/wp\/v2\/posts\/21942\/revisions\/21944"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/cpmirror.com\/index.php\/wp-json\/wp\/v2\/media\/21943"}],"wp:attachment":[{"href":"https:\/\/cpmirror.com\/index.php\/wp-json\/wp\/v2\/media?parent=21942"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/cpmirror.com\/index.php\/wp-json\/wp\/v2\/categories?post=21942"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/cpmirror.com\/index.php\/wp-json\/wp\/v2\/tags?post=21942"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}