Lucozade Energy bottles are set to feature a half sleeve that covers only 50% of the bottle height, a notable shift from the previous full-length sleeves. This modification will result in a 60% reduction in total sleeve weight, eliminating 956 tonnes of new plastic each year. Such an initiative is a significant step towards innovation in food and drink packaging, aligning with broader trends in the food and beverage industry.
Moreover, these changes are expected to drastically reduce water usage during production—equivalent to filling an Olympic-sized swimming pool every 289 days. Such advancements reflect the evolving landscape of food manufacturing trends and sustainable practices.
The successful project involved the installation of new sleevers across three production lines at SBF GB&I’s factory in Coleford. This endeavor required a collective effort of 470 working days and was completed in just six weeks, showcasing efficiency in food processing technology.
Additionally, this reduction in sleeve size enhances the recyclability of Lucozade Energy bottles. By ensuring that the reduced sleeve supports bottle-to-bottle recycling, it facilitates sorting into the clear plastics stream at recycling facilities, promoting a circular economy in the food and drink sector.
This initiative forms part of the manufacturer’s commitment to achieve 100% sustainable plastic across its portfolio by 2030. It also aligns with the company’s goals related to scope 3 emissions and net zero targets. Currently, packaging accounts for 15.5% of SBF GB&I’s scope 3 emissions. By eliminating 956 tonnes of plastic annually, the company aims for a 30% reduction in these emissions by 2030, reflecting a proactive approach to food and drink sustainability.
“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,” said Karl Ottomar, supply chain director for SBF GB&I.
“While reducing a drink’s sleeve size may sound simple, it has required a full redesign of the bottle and a complete change in componentry on our production lines. The team have dedicated thousands of hours to plan and 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.”
The evolution in packaging for Lucozade Energy follows similar enhancements in sleeve length for Ribena bottles in 2020 and Lucozade Sport in 2021, reflecting ongoing food and drink industry innovation.
SBF GB&I has invested a total of £11.3m over five years to advance its sustainable packaging efforts. The company actively collaborates with the industry to achieve a circular economy for plastics, including advocating for a deposit return scheme in the UK by October 2027.
The new Lucozade Energy bottles will also feature an ergonomic embossed design highlighting Lucozade’s ‘Arc’ logo, further enhancing brand recognition and texture. This aligns with current food and drink marketing trends.
The new bottles are now being rolled out into stores, marking a pivotal moment in food and drink consumer trends.
