Carlsberg Britvic & DS Smith: Recyclable, Circular Packaging
Carlsberg Britvic has entered a new partnership with DS Smith, designed to enhance sustainability and operational efficiency throughout the beverage company’s supply chain.
The collaboration focuses on reshaping operations as part of a wider bid to improve circularity and achieve carbon reduction targets.
The UK's largest multi-beverage supplier, Carlsberg Britvic’s portfolio includes well-known brands such as Carlsberg Danish Pilsner, Robinsons and Tango.
Carlsberg Britvic is now updating its supply chain by partnering with DS Smith, a global provider of sustainable fibre-based packaging, to introduce a more environmentally conscious packaging solution for its products.
Sustainable packaging and supply chain optimisation
The partnership involves an upgrade from the previous OTOR4 packaging to the new OTOR8 'Bag-in-Box' design.
This new packaging features an eight-sided shape, which, combined with higher-strength materials, makes it stronger than its predecessor.
A key outcome of this redesign is a reduction in packaging weight.
Calculations based on the weight of the former 7-litre packaging and the new 12-litre design show an 18.7% reduction for the old OTOR4 and a 10.5% reduction for the 12-litre version.
This weight decrease contributes to easier and safer handling for workers.
Furthermore, the redesigned shape allows for an average of 25% more boxes to be loaded onto each pallet.
This improvement reduces the number of pallets and lorries required for transportation and cuts down on the time employees spend loading and securing them.
“Every year Carlsberg Britvic produces more than 25 million litres of soft drinks to be served on dispense in pubs, clubs, bars and restaurants: and we couldn’t do this without high-quality, innovative packaging," says Tom Fiennes, Sustainability Director at Carlsberg Britvic.
"The new OTOR8 'Bag-in-Box' from DS Smith means sturdier packaging for our customers, reduced storage space for everyone and, from Pepsi MAX and 7UP to Tango and R.
"White’s lemonade, reduced carbon emissions: another milestone in Carlsberg Britvic’s journey to net zero carbon emissions.”
Reducing transport carbon emissions
The reduction in the number of pallets and lorries needed for transport directly decreases the environmental impact of the product journey.
The 115-mile journey between Carlsberg Britvic’s manufacturing site in Leeds and its national distribution centre in Lutterworth provides a clear example.
Based on average mileage and full pallet loads, the reduction in pallets and packaging weight is projected to save more than 50 tonnes of CO₂ transport emissions annually.
The benefits extend to warehouse operations where storage space is now used more effectively.
The packaging’s vertical design allows the boxes to fit together more securely improving stability.
This structural integrity lessens the risk of damage and potential leakage, which in turn reduces product waste.
Liz Manuvelpillai, Sales, Marketing and Innovation Director at DS Smith, says: “At a time when efficiency and sustainability remain front of mind for our customers, we’re thrilled to have delivered an effective packaging solution in collaboration with Carlsberg Britvic.
"Our innovation will see fewer consignment vehicles on the road, lower transport emissions and contribute to supply chain efficiency.
"Innovation and sustainability are at the heart of what we do as DS Smith and this is the first stage of the innovative 'Bag-in-Box' project as we support Carlsberg Britvic on their sustainability journey.”
A broader commitment to the circular economy
This packaging initiative is part of a broader sustainability strategy for both DS Smith and Carlsberg Britvic.
DS Smith’s design process considers circularity at every stage by focusing on elements such as:
- Design for reuse
- Supply chain optimisation
- Recyclability
- Planet safeness
- Material utilisation
- Renewable sources
- Recycled content
- Carbon footprint
For its part Carlsberg Britvic has demonstrated an ongoing commitment to carbon reduction.
According to Carlsberg Britvic 75% of the grid electricity used in its UK soft drinks manufacturing comes from solar panels.
Over the past three years it has also invested more than £9m (US$12.1m) in carbon-cutting technology.
This new partnership with DS Smith marks another deliberate step towards embedding efficient and sustainable practices throughout Carlsberg Britvic's supply chains, supporting its long-term environmental goals.
