Final Report

Glass lightweighting potential in the sparkling wine sector

An assessment of the opportunities for container glass lightweighting in sparkling wine sectors supplying the UK.

Project code: RPO024 Research date: January September 2009

Date: January 2010

Glass lightweighting potential in the sparkling wine sector

WRAP helps individuals, businesses and local authorities to reduce waste and recycle more, making better use of resources and helping to tackle climate change.

Written by: Mark Richmond of WSP Environment & Energy

Front cover photography: Popping the cork WRAP and WSP Environment and Energy believe the content of this report to be correct as at the date of writing. However, factors such as prices, levels of recycled content and regulatory requirements are subject to change and users of the report should check with their suppliers to confirm the current situation. In addition, care should be taken in using any of the cost information provided as it is based upon numerous project-specific assumptions (such as scale, location, tender context, etc.). The report does not claim to be exhaustive, nor does it claim to cover all relevant products and specifications available on the market. While steps have been taken to ensure accuracy, WRAP cannot accept responsibility or be held liable to any person for any loss or damage arising out of or in connection with this information being inaccurate, incomplete or misleading. It is the responsibility of the potential user of a material or product to consult with the supplier or manufacturer and ascertain whether a particular product will satisfy their specific requirements. The listing or featuring of a particular product or company does not constitute an endorsement by WRAP and WRAP cannot guarantee the performance of individual products or materials. This material is copyrighted. It may be reproduced free of charge subject to the material being accurate and not used in a misleading context. The source of the material must be identified and the copyright status acknowledged. This material must not be used to endorse or used to suggest WRAPs endorsement of a commercial product or service. For more detail, please refer to WRAPs Terms & Conditions on its web site: www.wrap.org.uk

Executive summary
This report has been produced for WRAP (Waste & Resources Action Programme) as part of the GlassRite Wine phase II project to look specifically at opportunities for glass lightweighting in the sparkling wine sector. Sparkling wines present additional complexities over still wines when considering glass lightweighting due to product pressurisation, production processes used and the premium branding associated with many sparkling wine products. This report seeks to establish the opportunities for lightweighting of glass bottles used to supply sparkling wine to the UK Champagne, where appropriate, is also considered. Specific aims for this research included:

To review sparkling wine production methods to understand factors that influence bottle specification. To evaluate technical requirements of glass bottles used for sparkling wines. To investigate the range of existing sparkling wine bottles available from glass manufacturers in key wine
producing countries.

To identify the potential for additional lightweighting based upon the outcomes of the above investigations.
In-depth information is provided on the four main production methods used to produce sparkling wine in order to identify the handling, storage and process requirements to which bottles are subjected. This is supported by the presentation of technical information relating to the manufacture of glass containers for carbonated products. A review of sparkling wine bottles available in key sparkling wine producing countries assists in identifying alternative lightweight bottles that could be adopted to deliver weight savings. Applying these identified weight savings to market data on UK sparkling wine imports suggests that a glass saving of up to 9,270 tonnes could be achieved through adoption of these lighter containers. This saving could potentially be increased up to 25,000 tonnes with further research into the appropriateness of lightweight sparkling wine bottles to different processes. The report recommends that further research may be required to identify additional glass savings that could be achieved beyond the adoption of existing lightweight containers. Specific focus for such research could include examining differences between specifications recommended by trade associations and specifications of bottles actually produced by manufacturers. Additional research could also examine the lightest possible bottle weight for the four main sparkling wine production methods and resulting product pressures.

Glass lightweighting potential in the sparkling wine sector

Contents
1.0 Background .............................................................................................................................. 3 1.1 Glass Container Lightweighting...............................................................................................3 1.2 Glass Lightweighting and the Sparkling Wine Sector ................................................................3 1.3 Glass Lightweighting and the Sparkling Wine Sector ................................................................4 2.0 UK Sparkling Wine Market ....................................................................................................... 5 2.1.1 Market Size and Value...............................................................................................5 2.1.2 UK Leading Brands....................................................................................................5 2.1.3 UK Sales Channels ....................................................................................................6 2.1.4 UK Sales Format .......................................................................................................6 3.0 Technical Requirements for Producing and Bottling Sparkling Wine ...................................... 8 3.1 Production Methods ...............................................................................................................8 3.1.1 Traditional Method ....................................................................................................8 3.1.2 Charmat Method .......................................................................................................8 3.1.3 Transfer Method .......................................................................................................9 3.1.4 Injection Method.......................................................................................................9 4.0 Sparkling Wine Bottle Requirements ..................................................................................... 10 4.1 Glass Container Manufacturing for Carbonated Products ........................................................ 10 4.2 Sparkling Wine Bottle Shapes ............................................................................................... 10 4.3 Bottling Pressurised Products ............................................................................................... 11 4.4 Technical Issues in Sparkling Wine Bottle Selection ............................................................... 11 4.5 Technical Specifications and Standards ................................................................................. 12 5.0 Sparkling Wine Producing Regions and Bottle Availability.................................................... 14 5.1 Australia ............................................................................................................................. 14 5.2 Chile ................................................................................................................................... 14 5.3 France ................................................................................................................................ 15 5.4 Germany............................................................................................................................. 17 5.5 Italy.................................................................................................................................... 17 5.6 New Zealand ....................................................................................................................... 18 5.7 South Africa ........................................................................................................................ 19 5.8 Spain .................................................................................................................................. 19 5.9 USA .................................................................................................................................... 20 Opportunities for Lightweighting....................................................................................................... 21 5.10 Summary of Opportunities ................................................................................................... 21 5.11 Opportunity for Lightweighting - Adopting Existing Containers................................................ 21 5.12 Opportunity for Lightweighting Further Research and Development ..................................... 24 6.0 Conclusions ............................................................................................................................ 25

Glass lightweighting potential in the sparkling wine sector

1.0

Background

This report has been produced for WRAP as part of the GlassRite Wine phase II project to look specifically at opportunities for glass lightweighting in the sparkling wine sector. One of the objectives of this flagship WRAP project has been to effect a comprehensive programme of glass container lightweighting amongst supply chains involved in producing, importing, distributing and selling wine into the UK. To support this objective, the research presented in this report has been undertaken to examine specific opportunities for lightweighting in the sparkling wine sub-sector. Information sources used in this research include market research organisations such as Mintel, contact with glass container manufacturers, sparkling wine producers and trade associations and glass manufacturing industry reference documents. Specific technical data and glass manufacturing industry information has been extracted from an internal briefing paper produced by Glass Technology Services for WRAP in 2008. Additional understanding and knowledge gained from a visit to the Comit Interprofessionnel du Vin du Champagne (CIVC), Saint Gobain Emballage, and the Moet & Chandon Champagne house in May 2009 has also been incorporated into the report. Some inconsistencies are apparent between data sources, notably related to market background and consumption, although these inconsistencies are not considered to be of significant magnitude to prejudice the reports findings.

1.1

Glass Container Lightweighting

Glass container lightweighting is an approach to waste minimisation that operates on a simple premise. By adopting lightweight glass containers during production, less packaging is placed into the supply chain which in turn reduces the amount of glass packaging disposed of or recycled post consumption. This contributes to reducing the amount of glass that is sent to landfill each year in the UK. Additional environmental benefits of glass lightweighting include the avoidance of natural resource extraction, primarily sand dredging and quarrying, and a reduction in CO2 emissions from the transport of products. Glass lightweighting can be undertaken in one of two ways. Firstly producers and fillers can work closely with specific glass manufacturers to produce new lightweight designs which will require the production of new mould sets. This approach is particularly applicable to those who hold a proprietary bottle design and the scheduled replacement of moulds presents an ideal opportunity to undertake lightweighting. The second means of container lightweighting is to identify lightweight alternatives from the wide range of bottles currently offered by glass manufacturers. Substituting lightweight bottles in this manner can be undertaken with greater ease and lower cost than developing new lightweight proprietary containers, especially if moulds need to be replaced prior to reaching their end-of-life.

1.2

Glass Lightweighting and the Sparkling Wine Sector

Sparkling wines present additional complexities over still wines when considering glass lightweighting. Firstly, the effervescent nature of sparkling wines generates an internal pressure which must be resisted by the glass bottle. Such pressures generated by sparkling wine are not uniform and are influenced by wine type and the production process used. The European Union (EU) Wine Regulations defines sparkling wines as having a minimum pressure of 3 Bar at 20oC in an enclosed container, although the majority of sparkling wines are pressurised to 6 Bar at 20oC. Bottles used therefore need to withstand these pressures and glass manufacturers provide pressure ratings to indicate internal pressure resistance which is a primary consideration in the selection of any sparkling wine bottle. The premium nature and subsequent branding of sparkling wines presents a non-technical challenge to introducing lighter weight bottles. Many sparkling wine brands invest heavily in product presentation and are nervous to make changes that could reduce luxury or premium attributes conveyed by packaging. Such changes could include reducing bottle wall thickness (yet maintaining pressure requirements), reduction in bottle height or the punt. The premiumisation and branding challenge over still wines is reflected in the price that sparkling wines command. This point is illustrated by comparing the recommended retails price of the UKs leading still wine, Hardys at 5.99 and the UKs leading sparkling wine (Moet & Chandon Champagne) at 29.99. An additional constraint to be considered in selecting sparkling wine bottles is the local availability of appropriate bottles. Different varieties of sparkling wine are usually produced at a sub-national regional level and bottle supply is often limited to supply by local glass manufacturers.

Glass lightweighting potential in the sparkling wine sector

1.3

Glass Lightweighting and the Sparkling Wine Sector

Specific aims for this research were identified in recognition of the complexities and constraints discussed above. These included:

To review sparkling wine production methods to understand factors that influence bottle specification. To evaluate technical requirements of glass bottles used for sparkling wines. To investigate the range of existing sparkling wine bottles available from glass manufacturers in key wine
producing countries. investigations.

To identify the potential for additional lightweighting based upon the outcomes of the above
Additional areas for further research have also been considered and identified in working towards the research aims stated above. This report only considers 75cl bottles, as this accounts for the majority of UK sparkling wines sales. The 75cl format is also where the greatest variety of bottles exists. Semi Sparkling wines (pressurised between 1 and 3 Bar) and products such as Lambrini (actually a Perry) have not been included in this research. The report also makes a distinction between the Champagne and non-Champagne sparkling wine sectors. As a sector, the Champagne industry is closely regulated by the Comit Interprofessional du Vin du Champagne (CIVC) which stipulates the production requirements of Champagne wines. This includes grape varieties used, production processes and glass bottles that may be used to fill Champagne. An approach to lightweighting across the Champagne sector is being coordinated by the CIVC which is outlined in this report (see boxed text on page 16). This report therefore focuses on lightweighting opportunities in the wider (non-Champagne) Sparkling wine market. References are made to Champagne only where appropriate, and for the avoidance of doubt, sparkling wine should be interpreted as non-champagne products.

Glass lightweighting potential in the sparkling wine sector

2.0

UK Sparkling Wine Market

This section provides information on the UK sparkling wine market including current and forecast volumes, leading brands and principal producing countries supplying the UK.

2.1.1 Market Size and Value

According to data collected by Mintel1, the UK imported around 71.3 million litres of sparkling wine and Champagne in 2007 consisting of 29.2 million litres of Champagne and 42.1 million litres of sparkling wine. This volume has increased steadily in recent years with an 8% and 20% increase in volumes for Champagne and sparkling wines respectively since 2005. Table 2.1 tracks the growth of champagne and sparkling wine consumption in the UK from 2002 to 2008.
Figure 2.1 The growth of UK Champagne and sparkling wine sales 2000-2008. 2

120

100

Million Bottles (75cl equivalents)

80

60

Sparkling Wine Champagne

40

20

0 2002

2003

2004

2005

2006

2007

2008

The steady and consistent growth experienced in the sparkling wine sectors is forecast to continue with Mintel forecasting annual growth of 4-5% throughout 20091. This is being driven through significant growth in demand for sparkling wines such as Italian Prosecco3. Growth of Champagne is only forecast to be around 1% for 20091 with the potential for a reduction in future sales resulting from a radical decision by the CIVC to reduce production by around 40% in the 2009 harvest4. It is estimated that the value of the UK Champagne market is around 958 million, with sparkling wine sales estimated at 385 million for 2007 (Mintel). The value split between the two sub-categories reflects differences in unit sales prices for 75cl bottles (the modal format). Champagne on average commands a price of 24.50 per bottle with sparkling wine averaging 6.40 per 75cl bottle in the off-trade sector.

2.1.2 UK Leading Brands

With relatively small scale domestic production, the UK is a leading export market for many sparkling wine producing regions. Indeed, the UK is the largest single export market for the Champagne sector, and is

Mintel Champagne and sparkling wine market intelligence, March 2008 Data sources include Mintel, CIVC and Glass Technology Services Compilation 2008 Reuters: Italys Prosecco Sets its Sights on Champagne (2008) Decanter.com: Champagnes Radical New Harvest Rules (2009)
Glass lightweighting potential in the sparkling wine sector

second only to Germany in the Cava sub-sector5. Of the sparkling wine consumed in the UK, Champagne makes up 41% of sales, and sparkling 59%. These are figures for 2007, and change is likely to have occurred over the past couple of years, with an increase in sparkling wine sales likely. Both Champagne and sparkling wine sales are dominated by branded products. Figure 2.2 illustrates this with sales value splits identified by Mintel (2008). This split is worth noting in relation to the aims of the GlassRite project as it indicates that lightweighting branded products is a priority for delivering significant weight reductions. Nevertheless, 40% of own-label sparkling wine is significant and also indicates that lightweighting would bring significant savings.
Figure 2.2 Comparison of branded and own label Champagne and sparkling wine UK sales6

Branded Sales (%) Champagne Sparkling Wine 95 60

Own Label Sales (%) 4 40

The large market share of branded products is held by a small number of large volume brands, particularly in the Champagne sector. Figure 2.3 below breaks down UK Champagne and sparkling wine sales (by market value) attributed to individual brands.
Figure 2.3 Leading UK Champagne and sparkling wine brands3

Champagne Market Share (%) 19.7 12 11.8 6.7 5.2 40.2 4.4 Estimated Market Share (m litres) 6 4 3 2 2 12 1

Sparkling Wine Market Share (%) 9.7 6.1 5.5 5.3 4.8 24.3 40.1 Estimated Market Share (m litres) 4 3 2 2 2 10 17

Brand Moet & Chandon Lanson Veuve Cliquot Laurent Perrier Bollinger Other Branded Own label

Brand Jacobs Creek Freixenet Martini Asti Codorniu Hardys Other Branded Own label

2.1.3 UK Sales Channels

The majority of sparkling wine is sold through the off trade sector for private consumption. This is again worth noting in relation to the aims of the GlassRite project as this split influences the amount of glass present in UK municipal and trade waste streams. Figure 2.4 identifies the specific on and off trade split for Champagne and sparkling wine:
Figure 2.4 Comparison of On and Off trade sales for Champagne and sparkling wines in the UK3

On-Trade Sales (%) Champagne Sparkling Wine 43 19

Off-Trade Sales (%) 57 81

2.1.4 UK Sales Format

Figure 2.5 below provides an overview of the most common formats of sparkling wine sold in the UK. This data relates specifically to the Champagne sector although it is thought to be reasonably representative of the
5

Personal communication with CIVC and FEV Data from Mintel: Champagne and Sparkling Wine Market Intelligence, March 2009.
Glass lightweighting potential in the sparkling wine sector

whole sparkling wines market. The percentages for each have been applied to the 71.3 million litres of Champagne and sparkling wine imported to the UK in 2008 to indicate the use of each bottle format.
Figure 2.5 Bottling formats used in the supply of sparkling wine
3

Container Volume 75cl 37.5cl 20cl Magnum (1.5l) Other

Format % 94 1.8 2.2 2 0.1

Millions of Bottles imported to UK 90 7.9 3 11.5 -

The majority of 75cl glass bottles used to fill Champagne and Sparkling wines are around 900g. Multiplying this against the 90 million 75cl bottles imported to the UK annually and factoring bottle utilisation identified in figure 2.5, would suggest that a minimum of 81,000 tonnes of glass packaging is imported annually to the UK by the sparkling wine sector.

Glass lightweighting potential in the sparkling wine sector

3.0

Technical Requirements for Producing and Bottling Sparkling Wine

This section reviews different production methods for producing sparkling wines and identifies typical product pressure and glass handling requirements during the process.

3.1

Production Methods

Four principle methods are used to produce sparkling wines on a commercial scale. Variations between these production processes influence how glass bottles are used and handled, and determines the bottle specification required in order to contain the finished sparkling wine. It is therefore important to consider the four production processes in detail prior to examining opportunities for bottle lightweighting. Information presented in this section has been gathered from visits to Champagne and sparkling wine production facilities and through personal communication with key wine industry representatives.

3.1.1 Traditional Method

Also known as the Mthode Champenoise for wines produced in the Champagne appellation, the traditional method is a two stage fermentation process used to produce a range of premium sparkling wines including Champagne, Cava and some New World sparkling wines. Juice from pressed grapes is subjected to primary fermentation in large tanks where processing can last up to one year. Wine produced in the primary fermentation process is then filled into glass bottles using similar filling equipment to still wines, typically consisting of bottle washing, a carousel filler and crown capping unit connected by conveyor. A temporary plastic closure and crown cap are used to seal the bottle at this stage which are extracted and discarded following bottle conditioning. Filled bottles are then stored in a first phase of maturation, commonly in caves (manmade underground tunnels) which enables secondary in-bottle fermentation to take place. The duration of this maturation varies amongst products from six months through to eight years in the case of some vintage Champagne wines. During storage, bottles are laid sideways and stacked in piles which can contain up to 20,000 bottles in a single stack. Stacking of bottles in this way exerts force on bottle contact points, which must be uniform in design to accommodate stack stability. Following the maturation a second stage of processing is undertaken. Bottles are racked upside down encouraging suspended yeast sediment (lees) to accumulate in the neck of the bottle. The neck of the bottle is then frozen capturing sediment in a plug which is disgorged from the bottle. A dosage of wine is then added to the bottle to compensate for volume loss in disgorging, and the final cork, wire and metallic capsule are applied to the bottle. In commercial production of sparkling wines these combined activities take place at speed along a conveyor to limit the time that bottles are open, limiting pressure loss. Much of the CO2 remaining is dissolved in the liquid and the product remains under pressure. Bottles can then be sent for further maturation and storage prior to bottle washing, labelling and packing. The final product pressure resulting from the traditional method process is influenced by the relative concentrations of dissolved sugar and yeast present in the secondary fermentation phase. Most Traditional method wines exert an internal pressure of around 6 Bar upon completion, with some examples as high as 8 bar. The use of glass bottles as a vessel for the secondary fermentation exerts a range of external loading and handling forces which must be considered alongside internal product pressure.

3.1.2 Charmat Method

The Charmat method or closed tank method of producing sparkling wine also involves two stages of fermentation, with both stages taking place in large stainless steel tanks. The Charmat method is used extensively in Italy for Prosecco wines and Germany, as well as some new world countries including Australia. Many French Vin Mousseaux are also produced using the Charmat Method. One of the main benefits of the approach is a reduced processing time compared to the Traditional method, with some wines ready for bottling within several months of the grape harvest. Juice from grapes is processed in a primary fermentation tank in a similar first step to the Traditional method. When the first phase of fermentation is complete, the wine is transferred into a second tank pressurised to around 5 Bar. All transfers of wine in the Charmat method are undertaken at low temperatures to retain high levels of dissolved CO2 within the wine.

Glass lightweighting potential in the sparkling wine sector

Secondary fermentation then takes place with the yeast lees filtered from the tank upon completion to produce sparkling wine ready for bottling. Wine may be held in a buffer storage tank prior to filling into glass bottles in a counter pressure filler. A cork and crown cap are applied along with wiring to secure the closure. The final internal pressure generated by sparkling wines produced by the Charmat method varies with examples identified between 2 and 7 Bar pressure. The range of handling and loading impacts exerted on glass bottles is significantly lower than in some other processes as bottles are not used in either phase of fermentation. The removal of many external handling and loading forces creates opportunities for using lighter weight glass bottles.

3.1.3 Transfer Method

The transfer method shares common elements with both the Traditional method and Charmat method using both in bottle and tank fermentation to produce sparkling wine. The approach is used to produce Asti Spumante wine in northern Italy and is also commonly used in Germany. As with the Charmat method, the time required to produce wines using the transfer method is significantly shorter than the Traditional method. Pressed grape juice undergoes primary fermentation in tanks and is then bottled using typical filling line equipment (i.e. bottle washer, carousel filler and crown capping unit connected by conveyor). Capped bottles are the sent for storage in caves where in-bottle secondary fermentation takes place. Bottles are typically stored for up to six months after which time the internal pressure exerted by the wine will be around 5 Bar. Following secondary fermentation, wine is extracted from bottles by puncturing caps, inverting bottles and injecting CO2 gas at around 2 Bar to force liquid out. Bottles used in the secondary fermentation process are rinsed and stored in preparation for final filling. The wine, which still contains the yeast lees, is stored in a pressurised tank where filtration and fining occur to remove sediment ready for bottling. One of the benefits of using the Transfer method is that blending of wines can be undertaken at this point in the process. The finished sparkling wine can then be stored in a buffer tank prior to bottling using a counter pressure filler. Individual wines produced by the Transfer method have a uniform pressure due to the mixing and filtration of wines following the secondary fermentation. Wines produced by this method typically generate an internal pressure of around 5 Bar. A variety of handling and loading impacts are exerted on glass bottles throughout the production process (although to a lesser degree than in the Traditional method) which should be considered when identifying lighter weight alternatives.

3.1.4 Injection Method

The Injection method of producing sparkling wine differs from other methods in that secondary fermentation is not used to provide natural carbonation of the wine. Instead the process uses still wine that has been filtered and stabilised to cease any fermentation. It is then carbonated artificially. Many entry level sparkling wines are produced using the Injection method reflecting the reduced production costs. Still wine is chilled before being passed through a carbonator, forcing compressed gaseous CO2 into the wine which is then stored in buffer tanks. Bottling is undertaken using a counter pressure filler prior to corking, capping and labelling. As carbonation is artificially created, the final pressure exerted by the product can vary significantly with examples ranging from 2 Bar to 5 Bar (although the upper limit is theoretically much higher than this). The dissolved CO2 resulting from the injection method dissipates rapidly once the product is opened as the carbonation is not naturally occurring.

Glass lightweighting potential in the sparkling wine sector

4.0

Sparkling Wine Bottle Requirements

This section provides information on the production of sparkling wine bottles and issues which should be considered in selecting a bottle for sparkling wine.

4.1

Glass Container Manufacturing for Carbonated Products

Glass containers are produced by one of two production methods. The blow blow (BB) forming process involves injection of nitrogen gas into both the blank and finishing moulds to blow the bottle. This differs from newer narrow neck press and blow (NNPB) process where a solid plunger is used to distribute glass around the blank mould prior to blowing with nitrogen in the finishing mould. One of the key differences between the two processes is that distribution of glass throughout the bottle is enhanced with NNPB which can help to reduce overall bottle weight. The majority of sparkling wine bottles are produced using the BB process which tends to lead to heavier container weights. The requirement for thick walls to contain the internal pressure generated by sparkling wines and the difficulty in achieving good glass distribution has led glass manufacturers to build generous safety margins to ensure a safe gauge of glass throughout the bottle wall. However, if rigorously controlled, the BB produced bottle can be made to tolerances close to those achieved by NNPB. This has been demonstrated recently by Allied Glass who successfully produced a 300g 70cl spirit bottle which is the lightest in class using the BB process. In practice, many long-established bottles were designed for BB manufacture at a time when process control was less well developed. These bottles therefore tend to be over engineered with greater safety factors with respect to wall thickness than would now be considered appropriate. On the whole, better process control in BB and the development of and increasing use of NNPB technology has enabled the production of lighter weight sparkling wine bottles which can be adopted to deliver weight savings and meet the tight technical requirements of a sparkling wine bottle. The continued development of NNPB technology by many of the larger international glass manufacturers provides further opportunities to lightweight sparkling wine bottles.

4.2

Sparkling Wine Bottle Shapes

As with still wines, sparkling wine bottles are available in a variety of styles. Bottle shape can sometimes reflect geographical provenance although product branding is usually the main driver in bottle selection. The standard sparkling shape (sometimes referred to as the Champenoise Standard) is the most common bottle shape used, whilst the skittle and butterfly shapes are also widely imported into the UK and are included in the country specific bottle review undertaken in section 5 of this report. Variants of each style exist between manufacturers although the key attributes of the three shapes are (see figure 4.1 overleaf):

Standard Tall Burgundy-like bottle with long sloping shoulders and a flat label panel. Commonly found
with a deep punt. A great weight variation in standard shape bottle exists with examples ranging from 575g to 900g7. Skittle Taking its name from a likeness to a bowling skittle, the bottle curves out from the base in a continual arc to form a gradual sloping shoulder and long bottle neck. Skittle shaped bottles commonly weigh around 900g7. Butterfly A comparatively shorter bottle rising out from the base to a bulbous shoulder profile. The joining of the bottle body with the short, narrow bottle neck creates a more defined shoulder profile. Butterfly shaped bottles typically weigh around 900g7.

Data obtained from a review of manufacturer online product catalogues presented in section 5 of this report.
Glass lightweighting potential in the sparkling wine sector

10

Figure 4.1 - Sparkling wine bottle shapes. (L-R) butterfly, standard and skittle.

4.3

Bottling Pressurised Products

The effervescent nature and consequential pressure exerted on bottles by sparkling wine is one of the single most important issues in selecting a sparkling wine bottle. Put simply, bottles must be able to withstand the internal pressure generated by products throughout the production, storage and consumption of the product. Glass manufacturers therefore provide maximum product pressure ratings for bottles designed to contain sparkling wines. Such ratings are usually expressed in Bar units and are provided as a guide to the types of sparkling wines that could be filled into the bottle. In practice the maximum internal pressure resistance of bottles is much higher than this value to provide a wide safety margin. Industry standards (discussed in section 4.5 below) define minimum pressure test values although in many cases manufacturers choose to work to much higher standards. Discussions with a leading Champagne bottle producer identified that minimum pressure test values exceeded the recommended industry value by around 15 Bar of internal pressure. This over specification of pressure rating may not be strictly necessary and further investigation in this area contrasting industry standards and manufacturers standards could potentially identify scope for weight savings. It should be noted that all pressure ratings are provided at a temperature of 20oC. Increasing the temperature of some products will cause product pressure to increase along with the internal force exerted on sparkling wine bottles. Most sparkling wines are served chilled at between 4oC and 7oC. At these temperatures internal pressure is reduced along with risks associated with breakages and bursts. The 20oC test value represents typical non-refrigerated room temperature storage conditions where internal pressure will be greatest and bottles will be manually handled by distribution staff and consumers alike. It is therefore essential from a consumer safety perspective that pressure ratings accord with the 20oC temperature standard.

4.4

Technical Issues in Sparkling Wine Bottle Selection

When selecting a bottle to fill, sparkling wine producers must take into account a range of technical considerations in addition to product pressure. Such considerations include the production process and transportation of finished products. Figure 4.2 summarises these technical considerations along with specific issues that must be taken into account in selecting a sparkling wine bottle.

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11

Figure 4.2 Technical considerations in selecting a sparkling wine bottle8

Issue Production process and bottle handling

Technical Considerations Is the bottle used for secondary fermentation? Are bottles stacked in free standing piles? Does riddling of sediment occur? Are bottles disgorged? Are bottles refilled (transfer method)? What is the mode of transport for export (i.e container) What distances and duration are involved in exports? Will significant temperature variations be experienced during transportation? What type of transport, and how will it be transported, once in the country of consumption?

Transport

These technical considerations are reflected in typical bottle weights used for the four methods of sparkling wine production. Wines made by the traditional method with in-bottle secondary fermentation and ridding of sediment are frequently found in bottle weights around the 900g mark. This is reflected when examining weights of bottles used for leading Spanish Cava wines. For wines produced by Charmat and Transfer method, a greater range of bottle weights are observed with many Italian sparkling wines using bottles weighing between 700g and 900g9. This reflects the reduction in handling processes incurred in production. This reduction is most marked in wines made by the injection method with examples such as Sainsburys basics sparkling wine using bottles as light as 575g.

4.5

Technical Specifications and Standards

All glassmakers work to some form of technical specifications which have been developed to provide guidance for the production of safe and serviceable products. Whilst the specifications are not legally binding, glass container manufacturers in many countries adopt a common standard. International technical standards set by the Centre Technique International de lEmbouteillage et du Conditionnement (CETIE) have been used to frame national guidance. The specification for pressurised glass containers is covered by Data Sheet DT 11 Standards & Procedures for the Control of Manufacture of Carbonated Beverage Bottles for Greater than 2g CO2/litre Carbonation. In the UK, the British Glass Manufacturers Confederation produces TEC 7 Strength and Performance Standards for the Manufacture and use of Carbonated Beverage Bottles which interprets the CETIE European standard. This includes details of the minimum pressure specification required for carbonated products as detailed in figure 4.3 overleaf. The standard also states that a carbonated beverage bottle should be able to withstand a vertical load of up to 75 Newtons per cm loaded.
Figure 4.3 Maximum internal pressure and test control criteria10

Max internal pressure exerted by product (bar) 3.0 3.6 4.7

Minimum Process control test value (bar) Non-refillable Refillable 10 12 14 12 14 16

Technical consideration identified during a visit to Moet & Chandon. Data presented to WRAP by Glass Technology Services (2008) TEC 7, Strength and performance standards for the manufacture and use of carbonated beverage bottles, British Glass.
Glass lightweighting potential in the sparkling wine sector

10

12

When considering these test values alongside the typical internal pressure generated by sparkling wines (between 3 and 6 Bar at 20oC) it is apparent that the values set by CETIE significantly exceed the likely requirements for safely packaging sparkling wines. This potential over specification is greatly increased when considering that Glass manufacturers typically work to higher standards than those set by CETIE, in some instances producing bottles rated up to 42 Bar11. The identification of over engineering of such magnitude presents an opportunity to undertake research examining whether such safety margins are required. Such research could explore the potential weight reductions and consequential glass waste reduction that could be achieved through reviewing theoretical and actual bottle pressure specifications.

11

Data presented to WRAP by Glass Technology Services (2008)

Glass lightweighting potential in the sparkling wine sector

13

5.0

Sparkling Wine Producing Regions and Bottle Availability

Global Champagne and sparkling wine production stands at around 2.1 billion bottles per year with the UK importing around 90 million 75cl bottles annually. This section provides information on the major sparkling wine regions that export to the UK, including an overview of local supply of glass bottles suitable for filling sparkling wine. Detailed information is provided on bottle weights available in key wine producing countries to assist the identification of lightweighting opportunities in country of origin. It should be noted that all bottle weights stated below are subject to a manufacturing tolerance of +/- 5g.

5.1

Australia

Wine Australia estimates that between 45 and 50 million bottles of sparkling wine are produced in Australia annually12. In recent years the Jacobs Creek brand has dominated the Australian share of the UK market and now commands an estimated 25% share of Australian sparkling wine consumed in the UK. Other major producers include Brown Brothers, Penfolds, Wolf Blass and Hardys. Wine Australia13 notes that sparkling wines has represented an area of significant growth in recent years. The majority of Australian sparkling wine imported to the UK is produced using the traditional method, although some are produced using the Charmat method. Australia has two container glass manufacturers that service the wine sector. Selection of sparkling wine bottles is limited in comparison to the selection of still wine bottles offered by these manufacturers. Figure 5.1 below identifies a selection of bottle weights for different styles of sparkling wine bottle produced in Australia.
Figure 5.1 Weights of 75cl sparkling wine bottles available in Australia14

Bottle Style Glass Manufacturer Amcor O-I Asia Pacific Standard 890g 680g 890g 850g 680g 890g 880g Skittle/Butterfly

Reviewing Australian sparkling wine bottle weights would suggest that two opportunities for weight savings exist. The first would entail a move from the heaviest bottles identified to 850g providing a unit saving of 40g. A second more significant programme of lightweighting to the 680g bottles available would require further investigation to assess the suitability of these bottles for sparkling wine produced using the traditional method, which makes up a sizable proportion of exports to the UK. Additional transit testing of any lightweighting would also be recommended due to the significant distance that bottled products travel to Europe from Australia.

5.2

Chile

Chile produces around 12 million bottles of sparkling wine per annum of which only around 1.6 million bottles are exported to overseas markets15. A high proportion of Chilean sparkling wine is produced using the traditional method. Casillero Del Diablo, produced by Concha y Toro, is one of the leading Chilean sparkling wines available in the UK. Chile has two container glass manufacturers that service the wine industry. Table 5.2 identifies the selection of bottle weights produced in Chile for different styles of sparkling wine.

12

Data presented by Efferescents du Monde (www.effervescents-du-monde.com) Wine Australia: Directions to 2025 report (2007) Data obtained from O-I and Amcor online product catalogues Data provided by Vielle internationale des techniques effervescents. (www.veille.viteff.com)
Glass lightweighting potential in the sparkling wine sector

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14

15

14

Figure 5.2 Weights of 75cl sparkling wine bottles available in Chile16

Bottle Style Glass Manufacturer Christalerias Chile Standard 900g 880g 790g 800g 660g Skittle/Butterfly

Christalerias Toro

The availability of a selection of bottles below 900g would suggest opportunities exist for moving towards lighter weight bottles for Chilean sparkling wines. Discussions with a leading Chilean producer suggest that the 790g bottle, produced by Christalerias Chile, is suitable for sparkling wine produced using the traditional method.

5.3

France

France produces approximately 515 million bottles of Champagne and sparkling wine annually, and is the global leader in sparkling wine production. France has a strong internal market for Champagne and sparkling wine which accounts for 64% of production with around 36% (approximately 185.4 million bottles) exported to foreign markets17. France produces a wide range of sparkling wines. Champagne is undoubtedly the most well known of these and accounts for some 57% of production (see boxed text overleaf). Regional Vin Mousseaux and Crmant, French terms used to describe sparkling wines outside the Champagne Appellation, comprise the majority of non-Champagne production. Figure 5.3 below identifies production volumes for the main types of French sparkling wine.
Figure 5.3 Annual production volumes of French sparkling wines18

Wine Style Val de Loire Crmant dAlsace Dont Saumur Crmant de Bourgogne Vouvray Blanquette de Limoux

Million of Bottles 25.5 22.1 9.2 8.36 7.6 5.6

Of these French sparkling wines Crmant de Bourgogne, Crmant dAlsace and Blanquette de Limoux are exported to the UK in significant volumes. Collectively these sparkling wines account for approximately 10% of UK sparkling wine imports (approximately 4.1 million bottles per year)19. All 4 main types of sparkling wine production processes are used in France. The traditional method is particularly common, being the sole method of Champagne production as well as the principal method of producing Crmant wines. Vin Mousseaux is commonly produced using Charmat or transfer techniques whilst some cheaper sparkling wines, usually created for export markets, are produced using the gas injection method.

16

Data obtained from ChristalChile and Christalerias Toro online product catalogues. Data provided by Vielle internationale des techniques effervescents. (www.veille.viteff.com) Data from Worldwide Intelligence of Sparkling Techniques Data Presented by Glass Technology Services to WRAP (2008)
Glass lightweighting potential in the sparkling wine sector

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18

19

15

As the Worlds largest producer of sparkling wine, France has a wide range of glass bottle options for filling. The sparkling wine sector is predominantly serviced by O-I Europe and Saint Gobain, and to a lesser extent Saverglass. Many French sparkling wines, including all Champagnes, are filled in 75cl bottles with an average weight of around 900g. Figure 5.4 identifies bottle weights for different styles of sparkling wine bottles manufactured in France.
Figure 5.4 Weights of 75cl sparkling wine bottles available in France20

Bottle Style Glass Manufacturer O-I Europe Standard 900g 840g 775g 560g 900g 800g 775g 630g 560g 900g Skittle/Butterfly 900g 910g

Saint Gobain

900g

Saverglass

900g

Many bottles filled with French sparkling wine are similar in style to the 900g standard used for Champagne. Lightweight bottles are offered by French glass manufacturers providing scope for lightweighting activity, subject to bottle compliance with product pressure and production processes. The recent introduction into Sainsburys product range of a French sparkling wine in a bottle weighing 575g exemplifies this.

Product Focus - Champagne

Champagne is sparkling wine produced using the traditional method. It is produced from a tightly defined 34,000 hectare appellation centring around Epernay in North Eastern France. As possibly the most widely known sparkling wine, Champagne is associated with premium and luxury attributes. The UK is the top export market for Champagne with around 39 million 75cl bottles imported annually (2008). Around 300 million bottles of Champagne are produced each year and all Champagne production is overseen by the Comit Interprofessional du Vin du Champagne (CIVC). As the trade body for Champagne producers, the CIVC aims to protect the industry, and provide guidance for all aspects of production, including appellation boundaries, allowable grape varieties, harvest times and yields, production processes and equipment use. The CIVC also approves sparkling wine bottles which may be used to fill Champagne. In 2007 the CIVC undertook a carbon footprint relating to production activities, becoming the first French appellation to do so. This revealed a carbon footprint of around 700g of CO2 per bottle of which 17% was attributed to wine bottle production. In response to this the CIVC have undertaken, in key areas, to reduce emissions by 25% by 2020 and by 80% in 2050. As part of the strategy to cut carbon emissions, the CIVC has been working with glass producers, including Saint Gobain, and leading Champagne houses such as Moet & Chandon and Mumm, to develop a light weighted Champagne bottle. The work, which has been ongoing for 10 years, aims to reduce bottle weight from 900g to 835g with around 100,000 trial bottles produced for production testing. The CIVC is carefully monitoring the trial and will make a decision in early 2010 on whether to approve the new bottle. If adopted, full savings could take up to two years to materialise in the UK as a result of the aging process and distribution. Based on current volumes, it can be calculated that up to a 3,800 tonnes per annum saving could be achieved from all non-vintage Champagne sales alone, potentially as soon as 2011.
20

Data obtained from O-I, Saint Gobain and Saverglass online product catalogues
Glass lightweighting potential in the sparkling wine sector

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5.4

Germany

Germany produces around 400 million bottles of sparkling wine annually21. This includes some 350 million bottles of Sekt, much of which is consumed within the domestic market. Indeed, Germany has a significant internal market, with 81% of consumption of sparkling wine being produced in the country. The major export market for German sparkling wines is Eastern Europe, with comparatively low volumes exported to the UK. The majority of German Sekt is produced using either the transfer or Charmat methods, with around 5% of premium Sekt produced using the traditional method. The finished product must have a minimum of 10% alcohol by volume and 3.5 bar product pressure. A significant proportion of German Sekt is produced using imported wines from France, Italy and Spain. Key players in the German market include Rotkappchen-Mum, Schloss Wachenheim and Henkell-Shnlein who collectively produce the majority of German sparkling wines. Germany has a large container glass market which is dominated by Ardagh Glass and O-I Europe. Wiegand Glas are also significant producers of bottles for the wine industry. Figure 5.5 identifies a selection of bottle weights for different styles of sparkling wine bottle produced in Germany.

Figure 5.5 Weights of 75cl sparkling wine bottles available in Germany22

Bottle Style Glass Manufacturer Ardagh Glass Standard 900g 775g 610g 775g 900g 870g 800g 650g 610g 560g 775g 640g 610g 570g 560g 590g Skittle/Butterfly

O-I Europe

Wiegand Glas

The widespread availability of lighter weight bottles in Germany, combined with the high use of the Charmat and transfer methods, would suggest a good opportunity for lightweighting.

5.5

Italy

The Italian sparkling wine industry produces around 253 million bottles per annum in a variety of styles including Prosecco, Asti and Lambrusco which are all readily available in the UK. The market is highly diversified with the leading three producers only accounting for some 40% of production. Approximately 43% of Italian sparkling wines are exported, around 3.5 million bottles per annum.23 A wide range of production methods are used in the Italian sparkling wine sector which reflects the various styles available. Asti Spumante, from the Piedmont region of northern Italy, is produced using the transfer method, whilst the production of Prosecco and Lambrusco uses the Charmat method. A range of other styles are also produced using the traditional method and gas injection techniques.

21

Data taken from Effervescents Du Monde (www.effervescents-du-monde.com) Data obtained from German glass manufacturer online product catalogues Data obtained from Vielle internationale des techniques effervescents. (www.veille.viteff.com)
Glass lightweighting potential in the sparkling wine sector

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23

17

Italian container glass manufacturing is also a highly diversified sector with a wide range of small scale producers, in addition to multinational manufacturers, such as. This has created a good range of sparkling wine bottles available in a variety of weights with the average available bottle weight being 750g. Figure 5.6 lists a selection of bottle weights for different styles of sparkling wine bottle produced in Italy.
Figure 5.6 Weights of 75cl sparkling wine bottles available in Italy24

Bottle Style Glass Manufacturer Bormiolo Rocco Standard 900g Skittle/Butterfly 900g 750g 700g 900g 800g 720g 600g 750g 600g

Saint Gobain Vetri

900g 700g 640g 600g 500g 750g 730g 700g 550g 500g 475g 900g 850g 600g

O-I Europe (A.V.I.R. spa)

Other

850g 750g

The widespread availability of lighter weight bottles combined with the large use of the Charmat process would appear to present a good opportunity for lightweighting in Italian sparkling wine sector.

5.6

New Zealand

New Zealand produces around 15 million bottles of sparkling wine annually. Approximately 3.3 million bottles of this are exported to the UK market each year. Leading New Zealand sparkling wine brands in the UK include Montana and Lindauer, both produced by Pernod Ricard. The New Zealand sparkling wine sector has historical links back to the Champagne region with some early settlers arriving in New Zealand from the Champagne region of France. This is reflected in the way the sparkling wine is produced, with most being produced using the traditional method. New Zealand has one container glass manufacturing plant operated by O-I Asia Pacific. This plant, based in Auckland, produces three different sparkling wine bottles at weights listed in table 5.7 below.
Figure 5.7 Weights of 75cl sparkling wine bottles available in New Zealand

Bottle Style Glass Manufacturer O-I Asia Pacific Standard 880g 660g Skittle/Butterfly 880g

Lighweighting in New Zealand would require further investigation to ascertain the suitability of the 660g bottle for the traditional method. Product transit testing may also be required given the significant freight distance from New Zealand to Europe.

24

Data obtained from available online Italian glass manufacturer product catalogues.
Glass lightweighting potential in the sparkling wine sector

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5.7

South Africa

South Africa produces around 9 million bottles of sparkling wine annually, of which around 4 million bottles are exported25. Cap Classique is one of the most common styles of South African sparkling wine and is produced using the traditional method. South Africa has two container glass manufacturers of which only one currently produces wine bottles suitable for carbonation. Details of available bottles are provided in figure 5.8 below.
Figure 5.8 Weights of 75cl sparkling wine bottles available in South Africa26

Bottle Style Glass Manufacturer Consol Standard 900g 800g Skittle/Butterfly

A single opportunity for lightweighting could be achieved by switching from the 900g to the 800g bottle, a weight reduction of 100g.

5.8

Spain

Spain produces approximately 250 million bottles of sparkling wine per year and is particularly known for the production of Cava. Approximately 63% of Spanish sparkling wine is exported to foreign markets4. Cava accounts for some 95% of annual Spanish sparkling wine production, which is approximately 220 million bottles produced each year. Cava is produced using the traditional method with production centering on the Penedes region of northern Spain. Data released by the Federacin Espaola del Vino (FEV) indicates that around 17 million bottles of Cava are exported to the UK annually27. The Cava market is dominated by two producers, Freixenet and Codorniu, who collectively produce 92% of all Cava28. The remaining 5% of Spanish sparkling wine, known as Espumoso, is produced using the traditional method, with a collective annual production of 1.15 million bottles. Freixenet also produce around 6 million bottles of non-Cava sparkling wine using the Charmat method. It is unlikely that significant volumes of these non-Cava Spanish sparkling wines are supplied to the UK market. The Spanish container glass industry comprises six companies, although Vidrieria Rovira (owned by O-I Europe), Vidrala, and Vicassa (part of the Saint Gobain Group) hold over 70% of the market. The majority of bottles used for Spanish sparkling wine are of a standard shape, with a variety of available bottle weights averaging 780g. Figure 5.9 lists the bottle weights for different styles of sparkling wine bottles manufactured in Spain.

25

Data presented by South African Wine Industry Statistics (SAWIS) 2008 Data obtained from Consol Glass online product catalogue Federacin Espaola del Vino export statistics 2008 Data obtained from Vielle internationale des techniques effervescents. (www.veille.viteff.com)
Glass lightweighting potential in the sparkling wine sector

26

27

28

19

Figure 5.9 Weights of 75cl sparkling wine bottles available in Spain29

Bottle Style Glass Manufacturer Vidrieria Rovira Standard 900g 660g 630g 900g 605g 585g 900g 835g 800g 900g Skittle/Butterfly 900g

Vidrala

Vicassa

Reviewing the sparkling wine bottles offered by Spanish bottle manufacturers, allows two opportunities for lightweighting to be identified. The first is for the majority of Cavas currently bottled at 900g to be moved to 800g. Recent discussions with some Cava producers have revealed that the 800g bottles available in Spain are suitable for use in the traditional method production process and could be adopted to deliver a weight saving. The second opportunity would be for producers not using the traditional method to consider moving to bottles around the 600g mark. Such a move would be dependent upon the suitability of these bottles to the handling stresses exerted by the traditional method employed in Cava production.

5.9

USA

The USA produces around 133 million bottles of sparkling wine annually, with around 86.6 million bottles produced for export markets30. The majority of American sparkling wine is produced in the Napa and Sonoma Valleys in Northern California. Several leading Champagne houses have invested in the Californian sparkling wine market and a significant proportion of production is therefore undertaken using the traditional method. The USA has glass manufacturing capacity dedicated to the wine industry located in California. This includes two sites operated by Saint Gobain and single sites operated by O-I and Gallo Glass. Table 5.10 below identifies a selection of bottle weights for different styles of sparkling wine bottles produced in the USA.
Figure 5.10 Weights of 75cl sparkling wine bottles available in the USA31

Bottle Style Glass Manufacturer O-I Saint Gobain Standard 900g 538g 900g 800g 600g Skittle/Butterfly

The variety of bottle weights available from USA glass manufacturers would suggest that opportunities for lightweighting exist. For traditional method sparkling wines this could involve a weight saving of around 100g achieved from moving to an 800g bottle. Any further savings would require further investigation to ensure compatibility with product pressure and handling in the production and transportation process.

29

Bottle data obtained from glass manufacturer online product catalogues Data provided by Vielle internationale des techniques effervescents. (www.veille.viteff.com) Data obtained fro O-I and Saint Gobain online product catalogues.
Glass lightweighting potential in the sparkling wine sector

30

31

20

Opportunities for Lightweighting

This section presents data on potential glass bottle weight savings that could be achieved in the sparkling wine sector following the review of production methods, bottle specifications and bottle availability in key wine producing countries.

5.10

Summary of Opportunities

One particular trend to emerge within data collected on available sparkling wine bottles is the distinction between three broad weight tiers. The first heavier tier includes bottles weighing from 800g through to 900g plus. The second intermediate tier contains mid weight bottles from 800g down to around 675g with the lighter tier including bottles from around 675g down to the ultra lightweight 475g. The identification of these three tiers presents two opportunities for bottle lightweighting. The first is to adopt technically suitable lightweight bottles within each tier to provide a lightweight saving of around 100g. For the heavier tier, this could involve a move from 900g to 800g using bottles that are currently available. For the intermediate and lighter tiers this could represent a move from 800g to 700g or from 675g to the around 575g mark respectively. The second opportunity is to migrate products from the heavier tier towards the lower tier. This option has the potential to provide significant weight savings although further research may be required to examine the technical suitability of these bottles to different product pressures and production processes as discussed in Sections 3 and 4 of this report.

5.11

Opportunity for Lightweighting - Adopting Existing Containers

Adopting existing or newly available containers at a lighter weight provides the easier lightweighting option for sparkling wine producers. This research has identified that in most countries a sufficient range of sparkling wine bottles are available to allow this, providing weight savings in the short term. To quantify the magnitude of this potential saving it is necessary to look at individual markets along with the weights of available bottles in respective regions. Table 6.1 below identifies typical existing bottle weights for various sparkling wines along with currently available lightweight alternatives. Indications of maximum available savings have been calculated based on import volumes presented in Section 4 above. The opportunities identified above are appropriate for both branded and own-label products sold in the UK.

Glass lightweighting potential in the sparkling wine sector

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Figure 6.1 - Potential lightweighting using currently available bottles in key wine producing countries

Sparkling Wine

Typical Bottle Weight

Lightweight Alternative

Annual UK Volume (Million bottles)

Total Packaging Weight (tonnes)

Potential UK Annual Glass Saving (tonnes)

Region Australia

900g Champagne* 900g Chile 900g France (excluding Champagne) Germany Italy 700g New Zealand 900g South Africa 900g Spain 900g USA 900g 750g 900g

800g 800g 780g 650g 775g 600g 800g 800g 800g 800g

13 38.8 0.5 4.1 1.2 4.6 3.3 0.3 22.6 7 90**

11,700 34,920 450 3,075 1,080 3,220 2,970 270 20,340 6,300 81,000**

1,300 3,880 600 410 150 460 330 30 2,890 700 9,270

* A trial is currently being undertaken by the CIVC, Saint Gobain and several Champagne houses. A final decision on the outcome of the trial is expected early 2010. ** Columns do not add up due to rounding.

The 9,270 tonne saving identified in figure 6.1 is expected to be realistic as the lightweight bottles identified are currently available for adoption, subject to production trialling to determine technical suitability. Assuming that the potential lightweighting identified in figure 6.1 would be undertaken for all markets including the UK, the global saving would be significantly greater. Figure 6.2 provides an indication of the wider, global glass savings that could be achieved. This represents added value to efforts incurred in achieving the UK saving.

Glass lightweighting potential in the sparkling wine sector

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Figure 6.2 - Potential lightweighting using currently available bottles in key wine producing countries

Sparkling Wine Region

Typical Bottle weight

Lightweight Alternative

Global Annual Volume (Million bottles) 50 400 12 115 400 253 15 9 250 133 1,637

Total Packaging Weight (tonnes) 45,000 360,000 10,800 86,250 360,000 177,100 13,500 8,100 225,000 119,700 1,405,450

Potential Global Annual Glass Saving (tonnes) 5,000 40,000 1,440 11,500 50,000 25,300 1,500 900 25,000 13,300 173,940

Australia Champagne Chile France (Excluding Champagne) Germany Italy New Zealand South Africa Spain USA

900g 900g 900g 750g 900g 700g 900g 900g 900g 900g

800g 800g 780g 650g 775g 600g 800g 800g 800g 800g

The second area of potential lightweighting activity would be to migrate products filled in bottles within the heavier tier (typically weighing 800-900g) to the bottle weight range found in the intermediate and lower tiers. This option has the potential to deliver greater weight savings than lightweighting within each tier, although it is likely that a significant level of research would be required in order to demonstrate to producers and brand owners that such lightweight bottles are fit for purpose. Such research would typically examine:

the internal pressure ratings of bottles; the suitability of lightweight bottles to different production processes; and consumer perception research.
Variations in production processes and product pressures create difficulty in forecasting the likely savings from this approach to lightweighting. If findings of further research identified scope for lightweighting of this magnitude, then it could be reasonably expected that potential savings would be significantly higher than those identified in Figures 6.1 and 6.2 above. To attempt to quantify the potential savings that could be achieved from this approach, potential weight reductions have been provided for three generic percentage reductions. Figure 6.3 details potential weight reductions for sparkling wines imported to the UK. This shows that a glass saving of around 25,000 tonnes could be achieved through lightweighting bottle weight by 30%. This would equate to moving from a 900g bottle to a bottle around 600g. the review of bottle availability in sparkling wine producing countries reviewed indicates that bottle availability would potentially allow lightweighting of this magnitude.

Glass lightweighting potential in the sparkling wine sector

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Figure 6.3 Indicative additional lightweighting for sparkling wine imported to the UK.

Sparkling Wine Region Australia Champagne Chile France (Excluding Champagne) Germany Italy New Zealand South Africa Spain USA

Typical Bottle weight 900 900 900

Lightweight Alternative 800 800 780

UK Annual Volume (Million bottles) 13 38.8 0.5

Total Packaging Weight (tonnes) 11,700 34,920 450

Total UK saving at 10% lightweighting 1,170 3,942 45

Total UK saving at 20% lightweighting 2,340 6,984 90

Total UK saving at 30% lightweighting 3,510 10,476 135

750

650

4.1

3,075

308

615

923

900 700 900 900 900 900

775 600 800 800 800 800

1.2 4.6 3.3 0.3 22.6 7 90

1,080 3,220 2,970 270 20,340 6,300 81,000

108 322 297 27 2,035 630 8,433

216 554 594 54 4,068 1,260 16,865

324 966 891 81 6,102 1,890 25,298

5.12

Opportunity for Lightweighting Further Research and Development

This research has also identified potential areas of research and development that could be undertaken at an industry level to facilitate additional lightweighting in the sparkling wine sector. The review of technical standards used by glass manufacturers identified that technical specifications are often exceeded in practice. An example of this relates to pressure rating where several manufacturers were found to exceed a recommended 17 Bar test value, sometimes by up to 25 Bar. Whilst it is recognised that this is undertaken to ensure container strength, further research could evaluate the reasons why specifications are exceeded by such margins and opportunities for reducing these in line with bottle weight. The increased use of Narrow Neck Press and Blow (NNPB) technology also provides scope for research to establish the lightest possible bottle weight appropriate for the various sparkling wine production processes. Undertaking production and trialling of lighter weight bottles would enable suitability to be assessed and would assist in building the case for further lightweighting.

Glass lightweighting potential in the sparkling wine sector

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6.0

Conclusions

The work undertaken within this research enables a number of key conclusions to be drawn regarding lightweighting in the sparkling wine sector.

A clear opportunity exists to reduce the 81,000 tonnes of glass packaging imported annually to the UK as
part of the sparkling wine and Champagne sector. Potential savings are based upon container shift to lighter, currently available bottles in the short term, with long term savings of a greater magnitude requiring further research and technical development. sparkling wine bottles currently available in key wine producing countries.

A potential glass saving of up to 9,270 tonnes could be achieved through adoption of lighter weight The high market share held by a few brands, potentially, provides future lightweighting initiatives with the
ability to deliver large savings in the sector by targeting relatively few brand owners.

A range of sparkling wine bottles exist at different weights in most sparkling wine producing countries that
supply the UK. The current availability of these bottles provides opportunities for short term lightweighting through container shift to lighter, currently available bottles subject to bottle suitability and brand equity. The ongoing work undertaken in the Champagne sector, where a new bottle approximately 65g lighter is being trialled, provides an example of how a sector can work together to make a step change with significant benefits.

Sparkling wine bottles can be broadly categorised into three weight tiers. The heavier of these tiers range

from around 800g up to 900g with the lighter tier ranging from 475g to around 650g. Opportunities for short term lightweighting lie within movements within each of these tiers (i.e. from 900g to 800g, or 650g to 500g). Significant lightweighting moves from the heavy tier to the lighter tier (i.e. 900g to 600g) would require further research and testing to ensure bottle suitability to product pressure and production process. in the sparkling wine sector is influenced by the production process used to create product carbonation. Introducing lighter weight sparkling wine bottles therefore requires careful consideration of handling, storing, processing and transportation requirements of the production process involved. wine producers exists. With respect to internal pressure ratings, some manufacturers are over engineering bottles, exceeding the 17 Bar minimum by up to 25 Bar. Future research should therefore consider the reasons for this, along with the potential for weight savings that could be achieved from reviewing this practice.

In addition to the internal pressure exerted on containers as a result of carbonation, glass lightweighting

Disparity exists between the technical specifications recommended by glass manufacturers and sparkling

The continued development and roll out of Narrow Neck Press and Blow (NNPB) technology will provide

new lightweighting options for sparkling wine bottles. Improving glass distribution in blow-blow moulds also provides opportunities to develop lighter weight sparkling wine bottles.

Glass lightweighting potential in the sparkling wine sector

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