How is it made? Aluminum can packaging manufacturing has undergone state-of-the-art processes for efficiency, sustainability, and precision to turn the raw aluminum into lightweight, durable, and recyclable containers for beverages, food, and other products.
The process begins with aluminum sheets created from alloys like 3104 or 3004, which balance strength, corrosion resistance, and malleability. These sheets are rolled to a thickness of approximately 0.25-0.30 mm. Each sheet undergoes a process called blanking, where circular disks are punched out to serve as the starting material for the can body.
These blanks are then formed into cylindrical shapes by drawing and ironing. Disks are pulled into tall, seamless cylinders at a high-speed press. This operation can reduce the wall thickness to as low as 0.10 mm and keeps the strength of the can. The drawing and ironing stages occur at speeds of over 2,000 cans per minute to ensure mass production efficiency.
Off the press, the cans are trimmed to uniform heights, coated internally with an lacquer that prevents corrosion and maintains the taste of the contents. This lining is food-grade, usually epoxy-based, withstanding temperatures up to 120°C without degradation through pasteurization.
The next step is the application of a decorative exterior coating. Advanced printing technologies apply up to eight colors in one pass and make accurate branding possible. As stated by the Can Manufacturers Institute, 85% undergo customization, making them the most critical marketing tool for marketers.
The top of the can is manufactured separately, with a double-seam mechanism that allows for a hermetic seal. This process, developed in the 1950s, minimizes oxygen ingress, extending product shelf life up to 12 months.
The recycling process is an integral part of aluminum can manufacturing. According to the Aluminum Association, more than 75% of all aluminum ever produced is still in use. Compared with producing aluminum from raw ore, recycling aluminum requires up to 95% less energy, hence providing substantial environmental benefits.
Steve Jobs once said, “Innovation distinguishes between a leader and a follower.” This holds true for aluminum can packaging since continuous evolution combines functionality and aesthetics with sustainability.
For more details on aluminum can packaging and its production, visit aluminum can packaging to learn how this versatile packaging solution is shaping industries worldwide.