Lucozade Energy unveils £6m sustainable packaging overhaul

Lucozade producer Suntory Beverage & Food GB&I (SBF GB&I) has invested £6.3 million in a major packaging redesign for Lucozade Energy bottles, significantly reducing plastic use and supporting the efficient recycling of its bottles.

Lucozade Energy bottles will now feature a half sleeve that covers just 50% of the bottle height compared to previous full-length sleeves. This results in a 60% reduction in the total sleeve weight, removing 956 tonnes of new plastic per year. The changes also reduce water use during production, equivalent to an Olympic-sized swimming pool every 289 days.

The project involved installing new sleevers with the latest technology across three different production lines in SBF GB&I’s factory in Coleford. The work took a collective 470 working days, delivered in only six weeks.

The changes are also important for the recyclability of Lucozade Energy bottles as the reduced sleeve continues to support bottle to bottle recycling. It ensures the bottle can be sorted into the clear plastics stream at recycling facilities allowing it to be recovered to create new bottles again.

Karl Ottomar, Supply Chain Director, SBF GB&I, comments: 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. While reducing a drink’s sleeve size may sound simple, it has required a full redesign of the bottle and complete change in componentry on our production lines. The team have dedicated thousands of hours to plan and then 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 new Lucozade Energy bottles will also feature a new ergonomic embossed design showcasing Lucozade’s iconic “Arc” logo, enhancing both brand recognition and bottle texture. The new bottles are now rolling out in store.