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RPC M&H Plastics - Garçon Wines’ rPET Flat Profile Wine Bottle

Product Name

Garçon Wines’ rPET Flat Profile Wine Bottle

 

What Made You Decide to Create This Product and Choose to Use Recycled Plastic Content? :

Garçon Wines has recently commissioned RPC M&H Plastics to produce a new kind of wine bottle. With a keen eye on the mail-order market – wine for the ‘Amazon generation’ – the innovative bottles have a flat profile while still retaining the classic shape expected by consumers. This enables the bottles to be packaged and delivered first time, through a letterbox. Reducing the carbon generated by failed deliveries (a major issue in mail order products) also has great environmental benefits. Using 100% recycled PET (rPET) to produce the flat wine bottles is something that Garçon Wines and RPC M&H Plastics believe to be unique in the wine industry as typically only a percentage of rPET is used in the production of bottles, and most plastic wine bottles are just PET. Pack weight is crucial in mail-order/e-commerce and the award-winning wine bottles, which are produced in rPET are 87% lighter than traditional glass bottles (63g vs. 500g). Therefore, transport costs and fuel used are reduced between the bottler and the final destination, thus reducing the carbon footprint and making it a more environmentally friendly solution. Garçon and M&H worked extensively on producing the optimal weight and wall thickness to ensure that the bottles were engineered to withstand the rigours of postal network distribution while retaining the glass like qualities of shine and clarity to best present the wines and look like the bottles we all know and love. Using 100% rPET was key to both companies’ corporate social responsibility values and the resulting bottle is produced from post-consumer recycled PET and can also be recycled to produce further bottles. Even the closure is plastic rather than aluminium to assist the recyclability of the product, after use. Garçon Wines are currently in discussions with companies to provide a future returnable bottle scheme to allow for empty bottles to be sent/collected and recycled, thus providing a completely ‘closed-loop’ production process.

 

What Were They Key Outcomes and Objectives That Lead You to Design This Product? :

Using 100% recycled PET (rPET) to produce the flat wine bottles is something that Garçon Wines and RPC M&H Plastics believe to be unique in the wine industry as typically only a percentage of rPET is used in the production of bottles, and most plastic wine bottles are just PET. The distribution of any product across great distances attracts significant costs and the weight considerations of transporting and distributing wine around the world contributes not only to the costs but also to the effects on the environment because of the fuel used from the vineyard to the final customer. The significant weight saving of using rPET for the bottles and the combination of reduced breakages will have a great effect on the overall environmental impact and carbon footprint of these bottles. The flat design of the product also allows for more efficient packing for transportation as there are fewer air-gaps in between the bottles as compared to a cylindrical bottle (approximately 40% space saving). Production of the bottles in rPET has many other benefits in production cost and raw materials saving and is proven to be more energy efficient per unit than traditional glass bottles. This also has the potential to make a closed loop, environmentally sustainable, production system as the bottles, once used, may be recycled and used to produce further bottles. The production of rPET compares favourably with glass (the prolific alternative with circa 37bn wine bottles produced per year) across production, transport and cost to recycle.

 

Outline The Development Phase of the Product:

Greater good: As we have seen in the world’s media, the careless disposal of plastic waste has had detrimental effects on our environment and wildlife. The challenge, therefore, is to educate customers regarding the potential re-use and recycling ability of plastic products. Garçon Wines is keen to be part of this educative process and will seek to demonstrate that the return of their bottles or placement into appropriate recycling schemes will not only save the customer money but will also have a direct effect on reducing and reversing the harm that historic disposal practices have led to. Fulfills a user need/ enhanced: Around 37bn bottles of wines are produced around the world each year and currently, the consumption of wines in the western world involves mostly purchase from supermarkets or specialist stores. Garçon Wines’ innovation has the potential to increase the volume of online wine sales due to the convenience of seamless delivery with bottles developed alongside RPC M&H Plastics which allows for a robust container that may be posted through households’ letterboxes without damage. The weight reduction of using plastic for the bottles has allowed for this to be possible and commercially viable. The presentation of the bottles has been found to be acceptable to customers as the rPET offers a glass-like finish even down to the delicate tinting of the rPET. Convenience achieved through the ordering process means that, depending on the courier method, an order can be placed while the recipient is out of the home and delivered so that the product may be enjoyed upon arrival in the evening. No need to make an extra trip to the retailer. Merchandising and motivates purchase: The ‘flat’ wine bottle is a talking point in its own right and will appeal to early-adopters greatly. The quality of the content will ensure that these early adopters will become loyal customers. Where the product is considered for retail placement, the advantage of displaying greater numbers of SKUs due to the smaller footprint creates retail efficiencies. The slightly higher stature of the Garçon Wines bottle also creates a greater sense of value as it stands taller than the competition, giving a perceived volume increase. Recognition of the product is also assisted as the bottle presents a flat front to allow for labels to be more prominent and therefore visible when compared to a label on a round bottle.

 

How Did You Monitor and Meet the Objectives That You Set? Where Appropriate Include Information On Research, Resourcing, Speed-To-Market, Material Selection, Testing and So On:

Responsible use: Using rPET in the manufacture of these bottles has the potential to make a closed loop, environmentally sustainable, production system as the bottles, once used, may be recycled and used to produce further bottles. The companies concerned are currently exploring methods to encourage responsible recycling with their customers to allow for a complete circular approach to the use and return of bottles for re-manufacture. Garçon Wines and RPC M&H Plastics are also exploring opportunities to ‘harvest’ re-process and use ‘Ocean plastics’ recovered from the sea in the manufacturing process. Efficient energy consumption: The production of rPET compares favourably with glass (the prolific alternative) across production, transport and cost to recycle. Reduction of waste through breakage is also a cost that has to be borne in mind. Reduction in Waste: rPET may be recycled many times without degradation to the material and this allows for the creation of a sustainable, circular flow of materials provided customers are educated regarding disposal. As has been seen recently, governments around the world are keen to promote this education and recycling of plastic waste and Garçon Wines are already looking to incentivise this process to work with partners to enable the bottles to be returned or appropriately recycled to reduce package waste. The ultimate aim is zero product to landfill.

 

What Is Special About the Product? :

Materials: Using 100% recycled PET (rPET) to produce the flat wine bottles is something that Garçon Wines and RPC M&H Plastics believe to be unique in the wine market as typically only a percentage of rPET is used in the production of bottles. The polymer used in the manufacture of the bottle is absolutely key to the success of this product. With the target of providing an efficient delivery method, the flat wine bottle has the ability to easily fit through a customer’s letterbox and be robust enough not to shatter, break or leak. rPET fulfils these criteria in a way that glass could not. Distribution: The distribution of any product across great distances attracts significant costs and the weight considerations of transporting and distributing wine around the world contribute not only to the costs but also to the effects on the environment of lorry and ship fuel used from the vineyard to the final customer. The weight saving of using rPET for the bottles represents an 87% of the equivalent weight of glass (for the same volume) and the combination of reduced breakages and lower weight to transport will have a great effect on the overall environmental impact and carbon footprint of these products. The flat design of the product also allows for more efficient packing for transportation as there are potentially fewer air-gaps in between the packages than would be seen with a cylindrical bottle. Production of the bottles in rPET has many other benefits in production cost and raw materials saving and is proven to be more energy efficient per unit than traditional glass bottles.

 

How Much Recycled Plastic Content Does Your Product Contain and Where Was This Sourced from? Please Include Information On Innovation, Design for Manufacture, Ergonomics, Aesthetics, Market Reception, Viability of Product Use, Purpose and Design for Sustainability:

Using 100% recycled PET (rPET) to produce the flat wine bottles

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