Automation behind a leap in sustainable bottle output

Our Efficient Motion Control technology powers Frugalpac’s new generation of high-performance Frugal Bottle Assembly Machines (FBAM-2), boosting output by more than fivefold.

A smiling man in a blue suit holds two bottles with unique labels in front of industrial machinery.

Malcolm Waugh, Geschäftsführer von Frugalpac

Who says a bottle has to be made of glass?

Frugalpac, a King’s Award-winning cleantech company based in Suffolk, UK, is revolutionizing the packaging industry with bottles made primarily from recycled paperboard and produced close to filling lines. Whether for wine, spirits or edible oils, these lightweight, containers offer clear sustainability advantages over glass: An independent life-cycle assessment conducted by Intertek in 2020 and updated in 2023 compared a 750 ml glass bottle with a 750 ml Frugal Bottle. Under the study's methodology, the Frugal Bottle had a water footprint at least four times lower, weighed 84% less (440 g vs. 70 g) and had a carbon footprint of 92 g CO₂e compared with 558 g CO₂e for the glass bottle – an 84% reduction. The paper outer shell and mono-material, polyethylene-based food-grade pouch can be separated and recycled through the appropriate local recycling streams, where available.

This lower-carbon packaging solution has caught on – so much so that Frugalpac has developed a new generation of machines to produce its Frugal Bottles: Frugal Bottle Assembly Machine 2 or FBAM 2. It increases annual output per line from around 2.5 million to over 14 million. Behind this leap are multiple innovations – from process and machine design improvements to a fully integrated automation architecture.

Glass vs. Frugalpac

* Source: Intertek in an independent lifecycle assessment (2020 and 2023) based on a 750 ml bottle.

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Lightweight

70 g per Frugal Bottle reduces material use and cuts the carbon footprint to 92 g CO2e versus 558 g CO2e for glass.

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100% recycled outer shell

Glass bottles typically contain around 35% recycled content; Frugal Bottles’ outer shell are made entirely from recycled paperboard.

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Proven impact

At 348 g of CO2e saved per Frugal Bottle compared with glass, over 4 million Frugal Bottles produced equals savings of 1,392 metric tons of CO2e.

A collaborative approach

The journey to FBAM 2 started with a strategic partnership in which we came together with Frugalpac and Underwoods, a certified Siemens Industry Distribution Partner. Over a period of ten months, the team worked on redesigning the machine control system to improve scalability, reliability and efficiency, while ensuring consistent processing of 100% recycled material. On the commercial side, Frugalpac is collaborating with Siemens Financial Services – our B2B financing arm – to offer tailored payment solutions to their customers.

"Through strong collaboration with Frugalpac and Underwoods, we transformed an innovative concept into a scalable, high-performance industrial solution that delivers beyond the output levels of conventional glass bottle manufacturing while supporting the production of lower-carbon packaging" comments Olly Gibbs, OEM Account Manager at Siemens.

A smiling man in a factory setting holds a bottle with a colorful label, standing in front of modern industrial machinery.<br/>

The solution consists of a complete controls package built around our Efficient Motion Control technology, including a Simatic S7‑1500 CPU for advanced motion control and Sinamics S120 servo drive systems with more than 20 coordinated axis movements. The result is precise coordination of the machine’s many moving parts, enabling higher speeds and consistent performance. Simatic HMI Unified Comfort Panels provide intuitive operator interaction and full transparency about machine status.

All components are fully integrated within the engineering platform TIA Portal, which brings software and hardware configuration – across PLCs, drives, HMIs, communication networks and safety – into a single project. This integration is supported by pre‑verified function modules, which accelerates development through reduced commissioning time and engineering effort. That means faster rollout and scaling. In addition, the network-based control architecture significantly reduces wiring requirements, allowing Frugalpac to achieve savings of up to 65% in wiring costs while enhancing system reliability and flexibility. So that Frugalpac’s people can get accustomed to working with the technology installed in FBAM 2 – such as TIA Portal and cybersecurity solutions – Sitrain courses are also part of the project.

Set for growth

All of this technology has made FBAM 2 significantly faster than its predecessor – it takes just three seconds to produce a single bottle. These higher speeds mean up to 30% lower overall bottle costs and faster returns. At the same time, the machine was designed with scale in mind to support the vision of a global fleet. Built-in cybersecurity standards ensure secure connectivity for remote installation support and lifecycle management, while connected data enables continuous monitoring and energy optimization. Furthermore, the experience gained with the FBAM 2 fleet will serve as the foundation for future machine generations.

A line of bottles with green-topped caps and white labels featuring green leaf designs and QR codes moves along a conveyor belt in a factory.

The FBAM‑2 gives the industry a practical way to move faster – cutting carbon, reducing costs and producing bottles closer to where drinks are made and sold.

Malcolm Waugh, CEO, Frugalpac

Beyond the Bottle: New packaging horizons

With its Frugal Bottle – made from recycled paperboard, lightweight and made close to bottling lines – Frugalpac is advancing its goal of offering lower-carbon packaging. Aside from bottles, Frugalpac is currently looking at extending its portfolio to include the Frugal Carton for everything from juice and milk to cereal and the Frugal Pot for holding paint. In all its activities, the company is committed to a high level of recyclability and to giving its customers greater control over the outside of their packaging for branding, advertising and other custom design elements.

About Frugalpac

The biggest innovation for wine and spirits since the launch of the glass bottle

The people at Frugalpac are motivated by a passion to reduce the impact of carbon on the planet through packaging that uses recycled paperboard. The company operates its own engineering innovation center in Ipswich, UK.