Extend the Life of Your Returnable Glass Bottle Fleet

make returnable glass bottles last longer make returnable glass bottles last longer
Apr 14, 2023

With limited supply of returnable glass bottles and steep price hikes in the cost of new bottles, learn how to extend your bottle fleet lifetime by up to 50% and significantly reduce your costs.


Beverage producers around the globe are suffering from price increases of up to 80% for new glass bottles and are under pressure due to limited supply. Worldwide logistics and supply chain issues have been exacerbated by soaring energy prices. This article discusses how you can reduce the inflated costs of purchasing new bottles with Diversey’s world-leading bottle protection solution and use bottles for 50+ cycles. In a free consultation, we evaluate your challenges and provide insights about your potential cost savings and your CO2, water & energy reduction.  


Why do beverage producers face price increases of up to 80% ...


Production costs of glass bottles skyrocketed as energy costs have massively increased lately because of the war in Ukraine. Beverage producers are confronted with price rises of up to 80% for new bottles, weighing heavily on their balance sheets. 

At the same time, returnable bottle fleets are under pressure. Bottle washer and conveyor systems stress bottles on each cycle they make through the packaging hall: etching the glass, fading ACL labels, or scuffing the bottle in the process. This damages the bottles’ appearance before they reach the consumer and ultimately impacts the brand at the point of sale.


… and risk harming their brand


The more a bottle is reused and refilled, the more the glass will degrade and scuff marks will appear that gradually worsen. Reducing production because of limited glass bottle supply will shrink revenue.

The information below describes our solution to help prolong the lifetime of returnable bottles and reduce purchasing costs for new glass bottles by up to 40%. Submit your information here if you want to be contacted by a Diversey representative about our BottleCare solution.


How you can extend the life of your bottle fleet by up to 50%


When bottles reach an etching degradation threshold, they are removed from the fleet and sent for cullet. This process typically occurs after the bottle has taken 20 trips to and from the market. By increasing the number of trips, you can maximize the return on investment in your bottle fleet. With Diversey’s BottleCare solution for returnable glass bottles, beverage producers can reuse bottles at least 50 times and save up to 40% of purchasing costs for new bottles. 

Efficient cleaning technology, along with protective coating, prevents damage and improves the appearance of returned bottles. They will look as good as new every time they re-enter the market.


Why maximizing sustainability keeps costs down 


Implementing BottleCare does not only enhance bottle appearance. It directly improves your environmental track record. Returnable or recyclable options remain essential to maximize sustainability. 

Manufacturing a new bottle requires a significant amount of energy in the form of gas to heat the furnaces and water for cooling. The industry averages emissions of 1.2 tons of CO2 for every 1 ton of glass bottles manufactured. A bottling line producing 45,000 bottles per hour can be optimized with BottleCare to save enough energy to power 300 homes for a year.

Running a reusable system is a brand-positive factor because your customers are aware of the environmental impact of energy use and emissions. They increasingly will prefer to buy beverages in refillable containers.

If you want to learn more about Diversey BottleCare, please arrange a free expert call with us here


Implement BottleCare in just 1 day


It’s conceivably simple to escape the dilemma of skyrocketing prices for new glass bottles and overstraining your current systems of treating returnable bottles: You can implement Diversey BottleCare in just one day; optimizing your systems for maximum return will take two or three days. The system is intuitive to use and requires just two hours of training. Companies of all sizes can benefit.

These would be the first steps to reducing your costs significantly: We would start with a production line audit and take on-site benchmark KPIs, such as the current bottle rejection rate, and determine a measurement of acceptable scuffing in light units with your team. Measurements are taken from bottles straight off the production line, after warehousing and after an ice-bath test to demonstrate the effectiveness of the maskant at the point in which the bottles enter the market.

Divobrite Defend, our next-generation bottlewasher additive, can be dosed through existing equipment. We monitor dosing during the initial set-up and optimize to achieve the optimum level of protection for your bottle fleet.


For Diversey DivoMask masking technology, we will review any existing application equipment and aim to adjust it to apply our maskant. Alternatively, we would install non-invasive application equipment. The applicator system design can be retrofit to your line without significant line alterations, avoiding additional cost and downtime. The stand-alone system is placed over a single-lane section of the conveyor and is fully adjustable to ensure that the spray nozzle and air blade system deliver the optimum application for your line and bottle design. Here you will find more information.

Get started with a free expert consultation with no obligation: We evaluate individual potentials for your company together with you. You will learn the following:


  • Benefits received from implementing Diversey BottleCare
  • How to benefit from best practice approaches 
  • What your journey might typically look like if you decide to work with us
  • Why we are the perfect partner for your challenge