Johnnie Walker bottle set for ‘virtual twin’ lightweighting trials

By Rachel Arthur contact

- Last updated on GMT

A 'virtual twin' model of the glass surface and coating interaction. Pic: Ardagh.
A 'virtual twin' model of the glass surface and coating interaction. Pic: Ardagh.

Related tags: Johnnie walker, Diageo, Lightweighting, Glass

Dassault Systèmes, Ardagh Group and EXXERGY will run ‘virtual twin’ trials on Diageo’s Johnnie Walker bottle, in order to research and develop a coating that will enable the glass bottle to be lightweighted without compromising its strength and shape.

A virtual twin is a real-time digital representation of a product or process that is used to model, visualise and predict new innovations before any physical trials take place. The aim of such virtual trials is to pioneer science-based sustainable innovations to reduce the time and cost needed to test glass products, while also reducing the raw materials and energy used in the process.

With the Johnnie Walker bottle, the trial will research and develop a new external coating for the glass bottle to reduce the naturally occurring micro-cracks in the glass surface, which will allow the glass to be much lighter while maintaining its strength. Trials are set to begin in January.

The lightweight glass bottle will maintain its 100% recyclability and if successful in the virtual trial, will undergo glass bottle testing from summer 2022.

Packaging company Ardagh Group will work with EXXERGY, a consulting firm active in the renewable and glass sectors, to research and develop the coatings for Diageo. Dassault Systèmes will provide contract research services using its BIOVIA applications to create a nanoscale virtual twin of the coatings, simulate their interaction with the surface of the glass, and test their efficacy.

“Glass lightweighting is one of the solutions for reducing the glass sector’s CO impact and carbon emissions will be reduced in both the manufacturing of the bottle and transportation of the finished goods,” ​say the partners. “Should this collaboration project be successful, it will be a major breakthrough for virtual twin technology in supporting the sustainability ambitions of the glass industry and enabling the decarbonisation of the sector as a whole.”

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