The Stoelzle Flaconnage Ltd site in Knottingley, West Yorkshire holds a long-standing history, adding to Stoelzle’s 200-year tradition of glassmaking, family-managed throughout the centuries. Production started in 1871, when the glassworks was known as ‘Bagleys’, named after the family owner. In the 1920s and 30s, the company became famous for its crystalline art deco style handmade pressed ware, which is still collectable today. The UK plant joined the Stoelzle Glass Group in 1994, thus becoming a part of a family-run company. By 2019, August Grupp, son of the owner Dr. Cornelius Grupp, joined the company as Head of Spirits Business Unit, ensuring that the family tradition continues.
Prestige spirits focus
In recent years, the UK factory’s job mix has focused almost entirely on the production of prestige spirits glassware, serving the high-end whisky, gin and vodka markets.
The Knottingley factory transformed successfully into a one-stop-shop for product development, design, manufacturing, and decoration, including the supply of closure applications for a variety of spirits bottles. Caps and closures are equally unique to the bottles that they become paired with; customers are able to choose from sustainable to high-end options as they work with Stoelzle closures experts. Designers and glass experts are committed to developing the perfect bottle for every single product, working closely with customers and supporting them from the initial sketch to the final bottle. More than 50 developments are brought to market per year, the most impressive gaining international recognition at packaging awards. The Stoelzle-manufactured Isle of Raasay single Malt whisky bottle was one of the winners at the UK Luxury packaging awards in 2021, while Austrian brand For Fellows’ 4x50 R.N.P Superior Rum – featuring a flacon made by Stoelzle from extra flint glass – was recognised at the 2022 WorldStar awards for global packaging excellence.
Production flexibility & sustainability
Saving raw material, reducing energy consumption and CO2 emissions have been identified as essential milestones in the Group’s sustainability roadmap, leading to significant investments made over the past few years.
In 2016, the site’s melting capacity was increased to 175tpd, including the option for 100tpd in the form of coloured glass. Provision was also made to supply tall ware (up to 575mm high) in extra white flint as well as colour compositions.
Previously unable to process post-consumer recycled (PCR) cullet due to the physical size and layout of its existing batch plant, in 2020, Stoelzle Flaconnage embarked on a project to build a 180-tonne silo along with conveying capabilities to feed PCR directly into the existing batch house. This major feat of civil and mechanical engineering is planned to be finished and in operation by summer 2022 and will enable the plant to run up to 30% PCR along with up to 20% internal cullet.
Further investments have been made in the field of compressors. Scheduled for completion by autumn 2022, the implementation of modern and more efficient equipment will help Stoelzle to save approximately 1,400MWh of electricity every year.
“As our CSR strategy focuses on three pillars, which are environment, employees and business partners, we are also engaged in continuous improvement training for workforce, not necessarily related to the recent investment but as part of site development and HR development in our operational areas. This will be cascaded down to the shop floor, with direct management levels receiving training in Lean, 5 S and 6 Sigma principles,” Thomas Riss, CEO of Stoelzle Flaconnage explains.
Innovation in decoration
Stoelzle Flaconnage’s site includes one of Stoelzle’s three decoration departments, where it promotes sustainable decoration processes and techniques. The company’s most recent development is ‘recycled ink’ (see Glass Worldwide November/December 2021, p.53). In collaboration with external experts, this new, environmentally friendly black printing ink was developed exclusively for Stoelzle. The carbon black used in colour pigmentations derives entirely from end-of-life tyres, which now have a sustainable purpose. The recycled ink not only saves carbon, which is a precious raw material, but also helps to reduce rubber waste. It is available in dark black, as well as shades of grey.
Delivering product differentiation
Decoration is a top priority for the continued success of the Stoelzle Flaconnage operation and the ability to deliver product differentiation. “Gold print is a great example of this, allowing the products we produce to stand out on the shelf at higher price points than those without print,” Mr Grupp observes. “It creates more of a luxury feel, depending on the complexity of the decoration.”
The company’s flexibility and design house techniques also provide opportunities for customers wishing to create a unique product. “Our technical ability to produce high value, coloured bottles with challenging shapes distinguishes us from our competitors,” adds Mr Grupp.
Recognised as the major prestige spirits producer in the Stoelzle Group, Stoelzle Flaconnage is performing well, especially in the UK. The ever-popular gin sector is an important business driver, while enquiry levels from the emerging rum sector are increasing. The factory’s latest investment initiatives are helping to support further business expansion. With more than 200 years of experience in the art of making glass, Stoelzle and its long-standing history will continue to drive innovation and growth for years to come.
Image: A bird’s eye view of the Stoelzle Flaconnage site in Knottingley, West Yorkshire (inset: August Grupp).