Frugalpac’s new FBAM-2 churns out 14M paper bottles yearly, slashing costs by 30% vs. Glass

UK – Frugalpac has introduced a faster production system for its paper Frugal Bottles, with the new FBAM-2 machine capable of producing 14 million units annually, more than five times the capacity of the earlier FBAM-1, while cutting the cost of paper bottles by up to 30 percent compared with existing alternatives.

The machine is intended for use at bottling plants and packaging sites across different markets, allowing bottles to be made nearer to filling lines, reducing cost, carbon output, and supply chain risk.

The system includes multi-lane configurations for both lower-volume and larger-scale production, offering flexibility for partners ranging from craft distilleries to major wine producers.

The Paper Bottle Revolution

The Frugal Bottle, launched in 2020, is made from 100 percent recycled paperboard and has a carbon footprint up to 84 percent lower than that of a standard glass bottle.

Since its introduction, more than four million Frugal Bottles have been produced and sold through retailers including Sainsbury’s, Aldi, Whole Foods, Target, and 7-Eleven.

The new 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.

Why Glass Is Losing Its Grip

Malcolm Waugh, CEO of Frugalpac, explained that for decades, glass has been the default for wine and spirits, but it is heavy, energy-intensive, and increasingly expensive to use and recycle.

He noted that packaging is no longer just a design choice but a climate decision, adding that 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.

He concluded that the opportunity is clear, the technology is ready, the future of packaging is lighter and lower cost, and the industry now has the tools to get there.

The Bottom Line

For the packaging industry, Frugalpac’s FBAM-2 addresses two persistent barriers to paper bottle adoption: production speed and cost.

At 14 million bottles annually, the machine matches the output of small to medium glass bottling lines while offering the flexibility of distributed manufacturing, bottles made at or near filling sites, eliminating long-distance transport of empty containers.

With costs now in line with or below labelled glass bottles, the economic case for paper bottles strengthens considerably.

For wine and spirits brands, the calculation is shifting: paper is no longer just an eco-friendly niche but a scalable, cost-competitive alternative to glass.

Subscribe to our email newsletters that provide busy executives like you with the latest news insights and trends from Africa and the World. SUBSCRIBE HERE