August 30, 2024 13:43
Plastic packaging supplier Berry Global and food distributor Abel & Cole have developed a polypropylene (PP) bottle that can be reused up to 16 times for the Club Zero Refillable Milk home delivery system, previously operated with glass bottles.
The lightness of PP containers compared to glass ensures a reduction in the carbon footprint due to lower emissions during production and transportation. Additionally, at the end of its use cycle, the plastic bottle can be easily recycled.
A study conducted by Abel & Cole indicates that reusing Club Zero Refillable Milk bottles just four times halves the carbon footprint compared to heavier glass bottles, which require over 15 returns to achieve similar emission savings. At the same time, this solution reduces the use of single-use plastic containers by 450,000 units per year, equivalent to 23 tons of material destined for landfill or energy recovery.
“When it comes to packaging materials, plastic is often seen as the enemy,” comments Hugo Lynch, Sustainability Lead at Abel & Cole. “But we challenged ourselves by asking whether it was better to use glass, which is heavier and more energy-intensive to produce, or to go against the grain.”
The first samples were 3D-printed for migration tests in June 2023, while the first bottles were delivered to customers starting in October. Since the launch, the distributor states, the one-liter Club Zero Refillable Milk bottle has recorded a 20% increase in weekly sales. The current return rate is 64%, but Abel & Cole aims to reach at least 75%.
The bottle's design is optimized to support Abel & Cole's eight-stage cleaning process, which eliminates the drying stage, reducing the risk of bacterial contamination. Additionally, the containers are handle-free to minimize areas where bacteria could accumulate. This ensures thorough cleaning of the container before it is filled in a clean room.
The design took into account the existing filling equipment at Abel & Cole's facility: for instance, the bottle was reverse-engineered to fit the low-density polyethylene (LDPE) cap to avoid investment in new equipment. For the same reason, the bottle fits the transport crates already in use for home deliveries.
The label provides comprehensive consumer communication to encourage returns, also featuring a "warning" system for the end of each bottle's life. In fact, it is designed to show signs of deterioration once the reuse cycle is complete. This allows Abel & Cole to visually monitor the bottle's lifespan and withdraw those destined for recycling.
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