Lucozade unveils US$8.36M eco-friendly bottle redesign to tackle plastic waste

UK – Suntory Beverage & Food GB&I (SBF GB&I), the manufacturer of Lucozade, has invested £6.3 million (US$8.36m) in a major redesign of its Lucozade Energy bottles, aimed at reducing plastic waste and improving recyclability across its portfolio.

The new design features a half sleeve that covers only 50% of the bottle’s height, reducing the sleeve’s weight by 60%.

This adjustment will eliminate an estimated 956 tonnes of plastic from the supply chain annually and significantly reduce water usage during production.

To implement the change, SBF GB&I installed new sleeving equipment across three production lines at its Coleford factory.

The upgrade, completed in just six weeks, involved 470 working days and required substantial coordination and technical precision.

Karl Ottomar, Supply Chain Director at SBF GB\&I, commented, “As one of the UK’s largest energy drink brands, producing over 3,000 bottles per minute, this has been a complex and large-scale transformation.

“Reducing a bottle’s sleeve size may sound simple, but it required a complete redesign of the bottle and replacement of key components on our production lines.

“The team invested thousands of hours into planning and execution, and I’m incredibly proud of their dedication in helping us achieve this major sustainability milestone.”

The redesign enhances recyclability by making the bottle more easily identifiable and sortable within recycling centres’ clear plastic stream—a crucial step in facilitating bottle-to-bottle recycling.

Industry organization Recoup confirmed that the new design meets recyclability guidelines.

Fraser McIntosh, Head of External Affairs and Sustainability at SBF GB&I, added, “This is a significant step in our journey toward 100% sustainable plastic packaging by 2030.

“Even amid rising cost pressures, we remain committed to our ‘Growing for Good’ values and continue investing in long-term environmental solutions for our brands.”

Packaging currently accounts for 15.5% of SBF GB\&I’s Scope 3 emissions. By removing nearly 1,000 tonnes of plastic annually, the redesign supports the company’s target of a 30% reduction in Scope 3 emissions by 2030.

Paul East, Head of Packaging Recycling and Design at Recoup, praised the move, “Recoup is proud to have supported the redesign of the Lucozade Energy bottle.

“It aligns with recyclability standards and significantly reduces plastic use. The next step is encouraging consumers to dispose of bottles correctly so they can be detected and recycled.”

The new bottles also feature an embossed “Arc” logo for improved grip and enhanced brand visibility. The redesigned packaging is now rolling out in stores across the UK.

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