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From advancements in sustainability to innovative designs, metal packaging manufacturers are developing solutions that are both functional and eco-friendly. FoodBev explores the trends and tech shaping the evolution of metal packaging and their influence on consumer preferences and environmental conservation efforts.

Metal packaging materials, such as stainless steel and aluminium, are widely employed in food and beverage applications due to their exceptional barrier properties, functionality and environmental credentials.

The metal can market thrives due to its transportation resilience, hermetic sealing, durability and recyclability. High aluminium can recyclability bolsters market growth, offering superior moisture protection and extended shelf life.

Amidst an aluminium can shortage, industry leaders invest in new manufacturing facilities to meet rising demand, as seen with Ball Corporation’s $290 million investment in a Nevada plant. Meanwhile, demand for health-oriented beverages like carbonated soft drinks and fruit juices is driving growth in the metal cans market, particularly in Europe, North America and Asia-Pacific.

Cans for climate change

All of Ball’s innovation efforts, as well as the advocacy work outlined in its Climate Transition Plan, are designed to offer customers effective solutions that help meet their decarbonisation goals.

“The beverage supply chain benefits from Ball’s innovations – for example, lightweighting practices,” said Mandy Glew, Ball’s VP of commercial for EMEA and Asia. “Since the 1970s, beverage can weights have decreased by more than 40% and today, cans can be produced with a wall thickness of 0.097 millimetres – as thin as a human hair.”

Ball’s STARcans represent an advancement in beverage can design, boasting up to 8% weight reduction compared to standard cans of a similar size. This helps retailers save on transportation and storage costs, and enables efficient stocking of shelves, ensuring timely product replenishment in the beverage aisle.

Ball’s ongoing collaboration with Carlsberg also serves as a testament to its commitment to sustainability. Over the course of three years, they have worked to reduce the weight of Carlsberg’s cans across more than ten European markets by approximately 5%.

“This lightweighting process has enabled us to collectively reduce carbon emissions by a staggering 5,000 tonnes a year,” Glew enthused.

Green and proud

Metal packaging manufacturer Trivium is also making sustainability a priority. The company recently won an award for its AmBev Budweiser limited-edition 2022 World Cup aluminium beer bottles.

“Responding to Budweiser’s brief, we created eye-catching bottles with the flags of the world champions printed on the vessels, reducing label waste and bringing the message of sustainability to the world stage,” said Alison Burns, strategic sustainability and beverage project manager at Trivium.

She added: “Compared to traditional glass bottles found on the market, Budweiser’s aluminium World Cup bottles were up to 80% lighter in weight, providing CO2 reductions in transport and energy savings in the brewing process”.

Trivium is focused on reducing the weight of its vessels, as Burns explained: “From threaded bottles and aerosols to beverage bottles and food cans, we are constantly testing our products to see how we can make them lighter, use less material and remain durable. With support from our R&D centre Trivium’s Cuxhaven plant in North Germany, we recently produced the world’s lightest aluminium seafood can.”

Additionally, Trivium has introduced the Easy Open End closure, which eliminates the need for a can opener with metal food cans, allowing consumers to effortlessly ‘pop’ open the top and peel back the lid. “Furthermore, we have designed an easy-peel end specifically tailored for products like nuts, coffee and yogurt, which typically use snap-top closures,” said Burns. “This solution not only provides a protective barrier but also ensures product freshness until the consumer is ready to open it.”

Reuse and recycle

US-based packaging supplier Crown remains committed to enhancing the sustainability of steel and aluminium cans by promoting responsibility and stewardship throughout its operations and partnerships across the value chain. The company’s ‘Twentyby30’ programme is dedicated to advancing industry recycling rates and implementing regional efficiencies at the plant level.

The programme sets 20 measurable goals to achieve by 2030, targeting areas like energy, water, greenhouse gas emissions reduction, renewable energy usage and responsible raw material sourcing. This involves initiatives such as reducing the weight of its cans by 10%, boosting metal packaging recycling rates and allocating at least half of its R&D efforts to minimise the environmental footprint in its products and manufacturing.

“These types of initiatives aim to further optimise the life cycle of cans, enhancing their utility as a sustainable packaging option for brands striving to achieve their own sustainability objectives,” said Veronique Curulla, marketing and business development director at Crown Bevcan EMEA.

Visual versatility

We are witnessing a significant transition from glass to metal packaging across various sectors, including wine, seltzers, RTD cocktails, water, soft drinks, as well as stocks, sauces and gravies. In January last year, UK supermarket Waitrose announced a transition from glass bottles to aluminium cans for its range of small wines. This shift allows customers to explore new varieties without concerns about wastage or cost.

Sustainable packaging producer Ardagh’s wine cans are noted for their suitability in preserving the quality and flavour profiles of wines. Its single-serve wine cans provide convenience and protection with air-tight sealing and durable construction. They are lightweight, stackable, made from 100% recyclable aluminium – compliant with legal regulations – and boast a 12-month shelf life.

The company says it is focused on ‘differentiation through decoration’. “Through cutting-edge technologies like our premium H!ghend line and digital printing via our partner Nomoq, we’re empowering brands to stand out on the shelf,” said Marc Bettinger, business development manager at Ardagh Metal Packaging Europe.

He added: “Examples like the great designs for Candy Can – which won the World Beverage Innovation Awards in 2023 – and collaborations with brands such as Britvic with Tango Mango showcase our dedication to pushing boundaries in decoration and differentiation, providing visually striking packaging solutions”.

Through innovative solutions and collaborative efforts, industry leaders are paving the way for a future where packaging not only protects products but also minimises environmental impact. With a focus on quality, convenience, visual appeal and environmental stewardship, the journey towards a more sustainable packaging landscape is well underway.

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