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Exploring new and sustainable economic opportunities, CBC Group's the CORE set off to develop a sustainable solution robust enough to replace 6-pack bottled beer case packaging by upcycling leftover BSG across the Group's breweries in Turkey, Israel, Romania, and Uzbekistan.
Product
6-Pack Beer
BSG Upcycling
TUBORG Beer
category
Upcycled Packaging
Key elements
Co-development
Robust packaging material development
Testing for continued improvment
Industrial-scale manufacturing
Packaging application
Background
Brewery Spent Grains (BSG) is an unexploited waste stream currently used mainly as animal feed. Accounting for 85% of beer production byproducts worldwide, these leftover 'used-up grains' are high in fiber, protein, and starch, making them an attractive solution for upcycled packaging.
challenge
solution
Sourcing: After sourcing spent grains from our Ashkelon brewery, the CORE joined forces with Nimrana Consulting to create a "duplex carton," primarily composed of BSG, turning waste into unique packaging material.
Manufacturing: Thanks to the expertise of Doron Harpak from Bezalel Graphics, the team designed, printed, and cut the "case" into a TUBORG 6-bottle pack.
Packaging: Haim Levy and Ashkelon Brewery (Carlsberg IBBL) teams came in to fine-tune the packaging line, ensuring the 6-pack was robust enough to hold beer bottles securely.
Testing: Throughout the development process, the CORE tested and re-evaluated the case's quality under challenging conditions involving transportation, cooling, shaking, and so forth, ensuring the case was ready to be safely carried away by all beer lovers.
results
After industrial, logistic, and consumer trials, the packaging met all the parameters of conventional packaging to replace duplex cardboard, saving tons of high-quality and expensive duplex cardboard.
Further, the functional and original marble patterned case won first prize in two different contests, the Israeli Packaging Institute of the Manufacturers Association of Israel (MAI)’s Star Contest and the World Global Packaging Awards for Packaging Materials and Components category, making it one of the most accomplished Environmental Packaging for 2024.
