UK-based sustainable packaging company Frugalpac has introduced a high-speed paper bottle manufacturing system aimed at scaling production of its paper-based bottles to meet rising global demand from beverage producers.
The machine—known as the Frugal Bottle Assembly Machine (FBAM)—is designed to enable localised production of paper bottles within bottling plants, co-packers, and packaging facilities. This decentralised production approach is intended to reduce transport-related emissions by allowing bottles to be manufactured closer to filling operations.
The system produces the company’s paper bottles, which are made from approximately 94% recycled paperboard and incorporate a food-grade inner pouch. Compared with traditional glass bottles, the format is significantly lighter—around five times—resulting in lower logistics costs and reduced carbon impact across the supply chain.
Each machine is capable of producing more than 2.5 million bottles annually, supporting industrial-scale adoption by wine, spirits, and olive oil producers. The technology also enables on-site bottle forming, which reduces the need to transport empty containers and can lower the number of delivery movements required.
Frugalpac’s model focuses on placing these machines globally to create distributed production hubs. This approach aligns with increasing demand for low-carbon packaging formats, particularly in the beverage sector, where the bottle can account for a significant share of total product emissions.
The paper bottle format also offers full-surface printability, enabling 360-degree branding, which is relevant for shelf differentiation while maintaining sustainability objectives.
With growing enquiries from international brands and packaging companies, the company is positioning its machine platform as a scalable alternative to conventional glass and plastic packaging, supporting the transition toward circular and lower-emission packaging systems.