Berry Global Supplies Abel & Cole with Refillable Polypropylene Milk Bottles

Last October, Abel & Cole introduced the first Club Zero Refillable Milk bottles. It was projected that these bottles could match the carbon footprint of the company’s single-use milk bottles after only four uses, whereas glass bottles would require over 15 returns to achieve similar savings.

With Abel & Cole’s annual sales of 600,000 bottles and an estimated return rate of 75%, this initiative is expected to save 450,000 single-use plastic milk bottles and reduce plastic usage by 23 tonnes.

The bottles from Berry are made from 100% ‘widely recyclable’ polypropylene and were reverse-engineered to be compatible with Abel & Cole’s existing low-density polyethylene milk bottle cap and other factory equipment, avoiding the need for further investments. They are also designed to fit into existing single-use milk crates.

Abel & Cole employs an eight-stage cleaning process that reduces bacterial contamination risks by eliminating the drying stage. The bottles are handle-free to minimize ‘trap points’ for bacteria and facilitate easy drainage. Berry conducted rigorous chemical tests to ensure the polypropylene bottles are strong and durable enough to withstand high processing temperatures, unlike their glass counterparts, which are prone to breaking. The labels on the bottles encourage consumers to return them and provide an ‘early warning’ system for end-of-life recycling by degrading as the bottle nears the end of its usability.

“When it comes to packaging materials, plastic is often seen as the enemy,” said Hugo Lynch, sustainability lead at Abel & Cole. “But we challenged ourselves to ask if it was better to use glass, which is heavier and more energy-intensive to make, or to go against the grain.”

Sue Springett, senior marketing manager for Berry Agile Solutions, added, “We are committed to delivering innovative, reusable packaging solutions that help our customers make transformative leaps toward their sustainability goals. Through circular partnerships like these, we unpack complexities and help our customers understand what’s possible for the plastic substrate.”

Since its launch, the one-litre Club Zero Refillable Milk bottle has seen a 20% increase in sales week-on-week. Abel & Cole reports a current return rate of 64% but aims for a minimum of 75%.

In related news, Milk & More and Again provided customers with refillable glass bottles and a complementary doorstep collection service in a trial with Tom Parker Creamery last year. This partnership was expanded to include additional dairy products and beverages from Brown Cow Organics, Belvoir Farm, and other branded products.

Milk & More also collaborated with Coca-Cola Europacific Partners to deliver reusable Coca-Cola Zero Sugar glass bottles to consumers’ doorsteps, which were then returned and refilled to reduce waste and greenhouse gas emissions.

Recently, dotch received two German Packaging Awards for its reusable glass bottle designed for pre-packed food. Consumers can return their empty bottles to any standard reverse vending machine, enabling smaller companies to adopt this solution.