For Melbourne’s Bodriggy Brewery, sustainability isn’t a slogan — it’s a series of conscious decisions made daily in the brewhouse, the bar and behind the wheel of the delivery van. So when Production/Packaging Manager James Graham noticed piles of single-use plastic keg caps that were ripped open and tossed aside, he knew there had to be a better way.
That small frustration sparked a collaboration with PakTech, the circular packaging specialists known for transforming recycled milk bottles into durable, fully recyclable handles and packaging products. Together, they’ve developed a new reusable Keg Kap that’s already saving waste and changing perceptions about what “sustainable packaging” really means.
From the start, Bodriggy has aimed to do things differently. The brewery — now carbon neutral and producing around 1.5 million litres of beer annually — has steadily refined its operations to reduce impact wherever possible.
“We’ve switched CO₂ suppliers to halve deliveries, changed our cardboard boxes to fit more on pallets, and looked at every way we can save fuel, packaging and water,” James says. “It’s not about flashy campaigns — it’s about the everyday decisions we make to be better.”
Packaging, however, posed one of the biggest challenges. While cardboard is often seen as the eco-friendly choice, James discovered that the coated cardboard used for six-pack wraps — designed to survive cold, damp conditions of refrigeration — isn’t always as recyclable as people assume due to wet-strength lining or additives. “There’s a bit of an education gap,” he says. “People think plastic equals bad and cardboard equals good, but that’s not always true.”
Bodriggy had already been using PakTech can carriers, made from 100% recycled HDPE — the same type of plastic used in milk bottles. Lightweight, strong and fully recyclable, these carriers can be reused multiple times before being collected for recycling back into new products.
“We run a program in our front bar where customers can bring back 10 and get a discount on their next pint so it keeps the loop going,” James says.
This circular approach aligns perfectly with Bodriggy’s philosophy. So when James started searching for a more sustainable alternative to single-use plastic keg caps, PakTech was the first call he made.
The concept for a reusable silicone-like keg cap began as a simple conversation. James wanted something lighter, cheaper and genuinely recyclable — a greener replacement for the rigid plastic caps that ended up littering delivery sites.
“I couldn’t find anyone who would make them,” he recalls. “Then I mentioned it to Rob from PakTech, and he said, ‘Leave it with me.’ A few weeks later, they’d prototyped exactly what I needed.”
The result was the new Keg Kap, a snug, reusable cover that protects kegs from dust and debris during transport and storage. Unlike single-use hard plastic caps, these Keg Kaps can be washed, reused and eventually recycled — and they’re now in use across all Bodriggy’s venues.
“They’re easier on bartenders’ hands, they don’t crack or tear, and they look cleaner,” James says. “We’ve got a bucket at each venue marked ‘Reuse Me,’ and they just go back into circulation.”
Early feedback from the team has been positive, even if James admits he’s “probably the most excited about a keg cap in the country!”
Since introducing the new caps in September 2025, Bodriggy has already seen tangible benefits. For Bodriggy, the reusable Keg Kaps are estimated to be around 30% cheaper than the single-use options they previously used.
The Keg Kap itself is designed with material efficiency in mind — using almost 50% less plastic than commonly used single-use alternatives — and each cap can be reused up to six times before being recycled, further lowering the environmental footprint.
With more than 15,000 kegs filled each year, that reduction in waste quickly adds up.
“It’s cleaner, smarter and more sustainable — a win for everyone,” James says. “Our accountant likes it because it’s cheaper, and I like it because we’re not sending plastic to landfill.”
The innovation fits neatly into Bodriggy’s broader sustainability journey — from monitoring glycol systems to reduce power use, to trialling biodegradable pallet wrap and pursuing CO₂ recapture systems as the business grows.
For both Bodriggy and PakTech, the project goes beyond operational gains. It’s also about reframing how the industry thinks about materials.
“There’s still a bit of misunderstanding out there about what sustainable packaging actually means,” James explains. “People think all plastic is bad, but that’s not the case when you’re closing the loop — using recycled materials, and then recycling them again.”
PakTech’s products are made from 100% recycled HDPE, and the company’s handles and caps are themselves fully recyclable — meaning every product can be reborn again and again.
“Plastic isn’t the villain if you’re reusing and recycling it properly,” says James. “It’s about being smart with the materials we already have.”
“I thought it, they listened, they made it,” James says simply. “That’s the best kind of partnership.”
Looking ahead, Bodriggy plans to expand its use of PakTech products and hopes to transition to clear, unpigmented can carriers — an even more recyclable option.
“It’s a small change, but across the industry it could make a massive difference,” James says. “If we can do it, anyone can.”
MADE FROM: 100% RECYCLED HDPE (EG. MILK BOTTLES)
REUSE RATE: UP TO 6X PER KEG CAP BEFORE RECYCLING
IMPACT: REDUCED LANDFILL WASTE AND IMPROVED CLOSED-LOOP RECYCLING
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