Paper Bottles Shaped with Leister Precision

Author: Dennis D'Arcy, South East Sales Executive, Welwyn Tool Group Ltd – Official Distributor  

 

Paper Instead of Glass – Turning an Idea into Reality 

The wine and spirits industry is under pressure. Declining sales, rising raw material costs, and higher transport expenses are driving the need for new solutions. The company Frugalpac, based in Ipswich, is responding with a radically different form of packaging: a bottle made of recycled paper, combined with an inner liner similar to a bag-in-box. 

The Frugal Bottle, a lightweight and fully recyclable paper bottle. Each bottle is up to five times lighter and has a carbon footprint up to six times lower than a traditional glass bottle. By combining sustainable materials with efficient production, Frugalpac proves that sustainable packaging and industrial performance can go hand in hand. 

Precise Heat for Perfect Shape 

Creating a durable paper bottle that can hold liquids safely requires precise heat at every stage of production. Working with Welwyn Tool Group, Leister’s exclusive UK sales and service partner, Frugalpac integrated Leister's robust blowers, LHS 21L air heaters, and HOTWIND SYSTEM into its automated production lines. 

These industrial hot air systems deliver consistent, controlled heat for forming and sealing paper bottles. During forming, the Leister heaters gently soften the pre-cut paper layers, allowing them to shape precisely around the mould cavity. At the next station, a custom-designed HOTWIND SYSTEM applies targeted heat to seal the bottle neck – ensuring strength, accuracy, and full recyclability. With this setup, Frugalpac now produces up to 500 paper bottles per hour – each one perfectly formed and sealed, ready for filling. 

“The Leister systems have been fundamental in bringing the Frugal Bottle to life. Their precision heating allows our recycled paper forms to shape perfectly and seal reliably, keeping our production sustainable and efficient,” says John-Paul Grogan, Product Director at Frugalpac. 

Technology Closing the Loop

The collaboration between Frugalpac, Welwyn Tool Group, and Leister shows how advanced heat technology supports the circular economy. Leister’s reliable and energy-efficient hot air systems help manufacturers worldwide reduce CO₂ emissions and improve production sustainability – without compromising performance or precision.

Leister and the Welwyn Tool Group thank Frugalpac for choosing Leister technology and for the constructive collaboration on this unique product. It’s a pleasure to support innovations that shape a more sustainable future in packaging.

Discover how Leister technology powers sustainable production around the world. We know how.