Industrial-scale paper bottle production is moving closer to mainstream adoption as packaging manufacturers look for practical ways to reduce carbon emissions while improving manufacturing efficiency.

British sustainable packaging company Frugalpac has expanded its paper bottle production technology with a new generation of automated manufacturing equipment developed in collaboration with Siemens. The upgraded production line is designed to help beverage producers manufacture paper bottles at significantly higher volumes while supporting lower-carbon packaging strategies.

Packaging Industry Faces Growing Pressure to Reduce Carbon

Glass remains the dominant packaging material for wine, spirits and many food products, but it is also one of the industry’s most carbon-intensive materials.

Manufacturing glass bottles typically requires furnaces operating at temperatures of around 1,500°C, resulting in high energy consumption. Rising energy prices, increasing production costs and tighter environmental regulations have placed additional pressure on glass manufacturers in recent years.

At the same time, Extended Producer Responsibility (EPR) schemes are making packaging producers increasingly responsible for the environmental impact of their products. Because glass is relatively heavy, it often carries higher transportation emissions and recycling costs than lightweight alternatives.

These factors are encouraging brands to evaluate alternative packaging formats that can reduce both emissions and logistics costs.

New Production Line Increases Manufacturing Capacity

Frugalpac’s Frugal Bottle is currently one of the few commercially available paper bottles designed for wines, spirits and edible oils.

The bottle uses 100% recycled paperboard as its outer shell while incorporating a food-grade inner pouch. Compared with a conventional 750 ml glass bottle weighing nearly 500 grams, the paper bottle weighs less than 100 grams.

According to the company, the design can reduce:

• Carbon footprint by 84%
• Water consumption by 76%
• Overall package weight by approximately 80%

Since commercial production began in 2020, approximately 4 million paper bottles have been produced, preventing an estimated 1,400 tonnes of carbon dioxide emissions.

The latest production system significantly increases manufacturing capacity.

The new automated line is capable of producing approximately 14 million paper bottles annually, representing more than five times the output of previous equipment.

Siemens Provides Automation Platform

Siemens supplied the automation platform supporting the new manufacturing system.

Its technology includes:

• Industrial automation architecture
• Drive systems
• Digital production control
• Manufacturing data transparency systems

The integrated system is intended to improve production speed, scalability and operational reliability while supporting industrial-scale manufacturing.

Automation also enables manufacturers to monitor production performance more effectively and improve process consistency as output increases.

Local Manufacturing Can Reduce Transport Emissions

Several beverage companies have already introduced wines, spirits and edible oils packaged in paper bottles across retail markets in the United Kingdom, Germany, the United States and Canada.

Rather than transporting empty glass bottles over long distances, some partners manufacture paper bottles locally using Frugalpac’s equipment.

Producing packaging closer to filling facilities can reduce transportation emissions while improving supply chain flexibility.

Paper Bottles Continue Expanding Beyond Pilot Projects

Paper bottles have gradually evolved from demonstration projects into commercial packaging options for selected beverage categories.

While glass will remain important for many premium products, lightweight fibre-based packaging is attracting growing attention as beverage brands pursue lower-carbon packaging and prepare for stricter sustainability requirements.

As automation improves manufacturing efficiency and production capacity continues to expand, paper bottles could become an increasingly practical option for brands seeking to reduce packaging emissions without significantly changing existing filling operations.

Last Updated on 28/07/2026 by Jota Machinery