Berry Global Group, Inc. (NYSE: BERY), a global leader in sustainable packaging solutions, has partnered with Abel & Cole, a trailblazer in food and drink delivery, to provide innovative bottles for its Club Zero Refillable Milk service. These new polypropylene (PP) bottles are designed to be refilled up to 16 times before they are recycled, setting a new standard in food and drink sustainable packaging.
Constructed from widely recyclable polypropylene (PP), these bottles result in significantly lower transport and processing greenhouse gas (GHG) emissions when compared to traditional glass bottles.* This innovative approach challenges the longstanding norm of using glass for home milk delivery, promoting a more eco-friendly alternative.
According to research from Abel & Cole, reusing the Club Zero Refillable Milk bottles just four times cuts the carbon footprint associated with their single-use milk bottles in half, especially compared to heavier glass options which require over 15 uses to achieve similar emissions reductions. Additionally, this initiative is projected to divert 450,000 single-use plastic milk bottles from landfills or incineration annually, equating to a reduction of 23 tonnes of plastic waste.
“When it comes to packaging materials, plastic is often seen as the enemy,” explained Hugo Lynch, Sustainability Lead at Abel & Cole. “But we challenged ourselves to ask if it was better to use glass, which is heavier and more energy-intensive to make, or to go against the grain.”
The design of these bottles has been meticulously optimized to enhance Abel & Cole’s eight-stage cleaning process. This process eliminates the drying stage, thereby minimizing the risk of bacterial contamination. Upon return, the bottles undergo thorough cleaning, ensuring they are completely sanitized before being refilled in a cleanroom environment.
To further enhance hygiene and ease of cleaning, the new bottles have been designed without handles, significantly reducing potential ‘trap points’ where bacteria could accumulate and allowing for efficient drainage. Moreover, the bottle has been engineered to be compatible with Abel & Cole’s existing factory equipment, such as the low-density polyethylene (LDPE) cap traditionally used for their milk bottles. This not only lowers production costs but also negates the need for new equipment, ensuring a seamless transition to sustainably packaged products. Additionally, the bottles fit into current single-use milk crates, offering a modern twist on the classic milk delivery model.
Berry has conducted rigorous chemical testing to confirm that PP provides the necessary strength and durability to withstand high processing temperatures, addressing the common issue of breakage associated with glass bottles.
Each bottle label features extensive consumer communication designed to encourage returns. The label serves as an ‘early warning’ system for the bottle’s lifecycle, as it can endure washing up to 16 times before showing visible signs of wear, allowing Abel & Cole to effectively track each bottle’s lifespan and ‘retire’ them for recycling when necessary.
Samples of the new bottle were 3D printed for migration testing as early as June 2023, with the first bottles dispatched to customers in October. Since its launch, the one-liter Club Zero Refillable Milk bottle has experienced a remarkable 20% increase in sales each week. The current return rate stands at 64%, with Abel & Cole aiming for a minimum target of 75%.
“We are committed to delivering innovative, reusable packaging solutions that help our customers make transformative leaps toward their sustainability goals,” stated Sue Springett, Senior Marketing Manager for Berry Agile Solutions.
“Through circular partnerships like these, we unpack complexities and help our customers understand what’s possible for the plastic substrate.”
*Based on research conducted by Abel & Cole
