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An improved can design by Coca-Cola Enterprises Ltd (CCE) and its project partners is making aluminium drinks cans 5% lighter, saving supplies of one the world’s rarest resources and delivering major improvements to the carbon footprint of canned drinks across Europe.

A report published by Wrap (Waste & Resources Action Programme) reveals that the new can design will save 15,000 tons of aluminium across the EU each year. The report says this translates to saving approximately 78,000 tons of CO2 – equivalent to taking nearly 25,000 cars off the road each year.

The specification has set a new standard across the EU, with major beverage brands and brewers already using the lighter can. 6.5 billion lightweight cans have already been produced and distributed. Next year, across Europe, more than 15 billion cans will be produced using the design.

These fundamental changes to the can manufacturing industry were initiated by Wrap and are the result of a significant commitment on the part of the project partners. CCE led the technical development of the can under full-time Project Manager, Christine Watson.

The new can design was developed and extensively tested in the UK at CCE manufacturing sites supported by Wrap, and in conjunction with BCME (Beverage Can Makers Europe).

The results establish two important firsts:

1. This is the first time the body of the can has been lightweighted in the EU – previous weight reductions related to the base of the can. As a result, the body of the new can is 0.097mm wide, which is about the width of a human hair.

2. Detailed scientific analysis of the can specification means that, for the first time, CCE and its partners can accurately predict the impact of proposed changes to the can design. This ensures no compromises on packaging quality. The cans are lighter but just as strong and robust as before.

Testing the limits of can design in this way also makes it easier for CCE and the BCME to identify options to further lightweight drinks cans in the future.

Hubert Patricot, European President for Coca-Cola Enterprises, said: “This work has changed the design of aluminium drinks cans forever. At CCE, we're committed to improving the sustainability of our business all the time. This project is delivering a significant reduction to the packaging carbon footprint of our business across Europe.”

Richard Swannell, Director of Retail at Wrap, said: “We're delighted to have achieved such ground-breaking results, and it just shows what cross-industry partnership working can deliver. Smarter packaging can deliver not only tangible cost savings to the supply chain, but also environmental benefits that help Europe tackle the joint challenges of climate change and resource efficiency.“