Inside Suntory's £25m Sustainable Manufacturing Investment

Suntory Beverage & Food (SBF) Great Britain and Ireland has announced a £25m (US$33m) investment to install a new high-speed manufacturing line at its facility in Coleford, Gloucestershire. 

The project, officially named Apollo 5, serves as the centerpiece of a broader £57m (US$76m) supply chain transformation programme at the site, which celebrates its 80th anniversary this year. 

This capital injection is designed to modernise the facility's infrastructure, ensuring it remains a primary hub for the production of Lucozade and Ribena.

The new production line, which uses aseptic technology – a more sustainable way of cleaning and filling bottles – is engineered to consolidate the manufacturing of these iconic brands into a single, streamlined system. 

Once operational in early 2027 – a date that coincides with Lucozade’s centenary – the line will be capable of producing up to 55,000 bottles per hour. 

This investment follows a decade of consistent upgrades at the Forest of Dean site, totaling more than £100m (US$133.9m), reinforcing the company's commitment to UK-based manufacturing and long-term industrial growth.

Michelle Norman, Director of Sustainability and External Affairs at SBF GB&I, says:  “From the earliest days of our factory in 1946 to how we are innovating today, our Coleford, UK site has been shaped by generations of talented people who care deeply about what they do.

“Today we are continuing that proud legacy with a multi-million investment in a new Lucozade and Ribena Line ‘Apollo 5’. It will be delivered by our incredible team blending local expertise and passion with Suntory’s Monozukuri spirit: craftsmanship, precision and continuous improvement.”

Operational consolidation and Apollo 5 Technology

The Apollo 5 line replaces two older Ribena lines that previously separated the production of concentrate and ready-to-drink (RTD) formats. 

By bringing these processes onto a single high-speed line, the facility significantly reduces operational complexity and overhead. 

The advanced technology allows for rapid changeovers between different brands and bottle sizes, providing the manufacturing agility required to respond to shifting consumer demands across the UK and Ireland.

Karl Ottomar, Supply Chain Director at SBF GB&I, notes: “We’re not just replacing factory lines; we’re embracing new technology to future-proof our operations and make them more efficient. 

“This new line is a big step forward, giving us the capability to keep growing and innovating.” 

The installation requires sophisticated engineering work within the existing factory footprint, optimising the layout to integrate the new technology without disrupting current production schedules for Lucozade Sport and Ribena.

Furthermore, the project delivers a notable boost to the regional economy. Approximately £2.1m (US$2.8m) of the total investment is expected to be spent directly with regional organisations across Gloucestershire, Herefordshire, and South Wales during the construction and implementation phases. 

This local spending supports a network of specialised contractors and suppliers, emphasising the factory’s role as an economic anchor in the Forest of Dean.

Sustainability through aseptic innovation

A defining feature of the Apollo 5 line is its use of aseptic technology, which utilises heat and pressurised air rather than water to clean bottles before the filling process. 

This innovation significantly lowers both energy and water consumption, aligning with Suntory’s global ‘Mizu To Ikiru’ (Living with Water) promise. 

By reducing the volume of water required for sterilisation, the plant improves its overall resource efficiency and minimises the environmental impact of its high-volume output.

This investment follows a recent £6m (US$8m) sustainability initiative launched to electrify the Coleford site and reduce its reliance on traditional gas turbines. 

By integrating more energy-efficient hardware and moving toward electrified processes, SBF GB&I is advancing its ‘Growing for Good’ vision. The facility already utilises 100% renewable electricity and maintains a zero-waste-to-landfill status.

The project marks the next chapter for the Coleford factory as it evolves into a digitally-enabled, sustainable manufacturing hub. 

By combining 80 years of heritage with modern automation, Suntory Beverage & Food aims to secure the facility's competitive edge within its global supply chain. 

The investment ensures that manufacturing growth is decoupled from environmental impact while sustaining hundreds of skilled roles and supporting the company’s vision of delivering high-quality products through a more conscious production network.