Why is aluminium the choice of metal for packaging?<\/strong><\/h2>\n\n\n\nBefore getting into the process, it helps to understand why aluminium is the go-to material for cans in the first place.<\/p>\n\n\n\n
\n- It is lightweight and is thus easier and cheaper to transport<\/li>\n\n\n\n
- It can hold pressure without cracking or warping<\/li>\n\n\n\n
- It doesn’t rust like steel<\/li>\n\n\n\n
- It is 100% recyclable and can be reused indefinitely<\/li>\n\n\n\n
- It acts as a good barrier by keeping out light, air and moisture<\/li>\n\n\n\n
- It chills faster than glass or plastic<\/li>\n<\/ul>\n\n\n\n
Aluminium also has a long shelf life and keeps contents fresh without affecting taste. That matters a lot in food and beverage packaging.<\/p>\n\n\n\n
Aluminium can manufacturing process<\/strong><\/h2>\n\n\n\nHere’s a step-by-step look at how aluminium cans are made from a flat sheet of metal to the finished container on a shop shelf.<\/p>\n\n\n
\n![\"Aluminium](\"https:\/\/www.alcircle.com\/blog\/wp-content\/uploads\/2026\/05\/AL-Biz-Blog-images-for-AL-Circle-1024x683.jpg\")
<\/a><\/figure>\n<\/div>\n\n\nStep 1: Sourcing and preparing the aluminium<\/strong><\/h3>\n\n\n\nIt all starts with aluminium alloy sheets. These are typically made from a mix of primary aluminium (from bauxite ore) and recycled aluminium. The sheets are rolled to a precise thickness, usually around 0.25 mm to 0.30 mm, at a rolling mill<\/mark><\/a>.<\/p>\n\n\n\nThe alloy used for can bodies is usually 3004 aluminium sheet<\/mark><\/a> or 3104 aluminium coil<\/mark><\/a>, which offers the right balance of strength and flexibility. The lids use a slightly different alloy, often 5182<\/mark><\/a>, because they need to be stiffer.<\/p>\n\n\n\nStep 2: Blanking and cupping<\/strong><\/h3>\n\n\n\nThe aluminium sheet is fed into a cupping press. This machine punches out circular discs (called blanks) and immediately forms them into shallow cups.<\/p>\n\n\n\n
\n- Thousands of cups can be produced per minute<\/li>\n\n\n\n
- The process is very fast and highly automated<\/li>\n\n\n\n
- Scrap metal from the punched-out areas is collected and recycled on-site<\/li>\n<\/ul>\n\n\n\n
Step 3: Drawing and wall ironing (DWI)<\/strong><\/h3>\n\n\n\nThis is one of the most important steps. The shallow cup is pushed through a series of dies in a process called Drawing and Wall Ironing (DWI).<\/p>\n\n\n\n
Here’s what happens:<\/p>\n\n\n\n
\n- The cup is redrawn to reduce its diameter<\/li>\n\n\n\n
- It’s then ironed; pushed through rings that thin the walls while making the can taller<\/li>\n\n\n\n
- The base is shaped into a dome (this helps it withstand internal pressure)<\/li>\n<\/ul>\n\n\n\n
By the end of this step, the can has reached close to its final height and shape. The walls are extremely thin, but very strong.<\/p>\n\n\n\n
Step 4: Trimming<\/strong><\/h3>\n\n\n\nThe top edge of the can isn’t perfectly even after the DWI process. A trimmer cuts the top to make it uniform and level. The trimmed metal is recycled.<\/p>\n\n\n\n
Step 5: Washing and cleaning<\/strong><\/h3>\n\n\n\nThe can is washed thoroughly to remove:<\/p>\n\n\n\n
\n- Lubricants used during forming<\/li>\n\n\n\n
- Metal particles<\/li>\n\n\n\n
- Any surface contamination<\/li>\n<\/ul>\n\n\n\n
This is important for food safety and to help the coating and printing bond properly.<\/p>\n\n\n\n
Step 6: External coating and printing<\/strong><\/h3>\n\n\n\nOnce clean and dry, the outside of the can is coated with a base coat (usually white or clear). Then it’s printed using a dry offset printing process.<\/p>\n\n\n\n
\n- Up to 6 colours can be applied in one pass<\/li>\n\n\n\n
- The ink dries almost instantly using UV or thermal curing<\/li>\n\n\n\n
- A protective lacquer is applied on top to protect the print<\/li>\n<\/ul>\n\n\n\n
This is where branding, nutritional info, barcodes and design elements are added.<\/p>\n\n\n\n
Also read: Surface treatment guide for fabricators<\/mark><\/a><\/p>\n\n\n\nStep 7: Internal coating<\/strong><\/h3>\n\n\n\nThe inside of the can is spray-coated with a food-grade lacquer or epoxy lining. This coating:<\/p>\n\n\n\n
\n- Prevents the contents from reacting with the metal<\/li>\n\n\n\n
- Protects the aluminium from acidic or carbonated drinks<\/li>\n\n\n\n
- Keeps the taste and quality of the product intact<\/li>\n<\/ul>\n\n\n\n
The coating is then cured in an oven to harden it.<\/p>\n\n\n\n
Step 8: Necking and flanging<\/strong><\/h3>\n\n\n\nYou might have noticed that the top of the can is slightly narrower than the body. That shape is created in the necking stage.<\/p>\n\n\n\n
\n- The top is compressed inward in multiple steps to form the neck<\/li>\n\n\n\n
- A flange (a small outward lip) is then added at the very top<\/li>\n<\/ul>\n\n\n\n
The flange is what the lid seals onto later, once the can has been filled.<\/p>\n\n\n\n
Step 9: Quality inspection<\/strong><\/h3>\n\n\n\nBefore cans leave the factory, they go through strict checks:<\/p>\n\n\n\n
Aluminium also has a long shelf life and keeps contents fresh without affecting taste. That matters a lot in food and beverage packaging.<\/p>\n\n\n\n
Aluminium can manufacturing process<\/strong><\/h2>\n\n\n\nHere’s a step-by-step look at how aluminium cans are made from a flat sheet of metal to the finished container on a shop shelf.<\/p>\n\n\n
\n<\/a><\/figure>\n<\/div>\n\n\nStep 1: Sourcing and preparing the aluminium<\/strong><\/h3>\n\n\n\nIt all starts with aluminium alloy sheets. These are typically made from a mix of primary aluminium (from bauxite ore) and recycled aluminium. The sheets are rolled to a precise thickness, usually around 0.25 mm to 0.30 mm, at a rolling mill<\/mark><\/a>.<\/p>\n\n\n\nThe alloy used for can bodies is usually 3004 aluminium sheet<\/mark><\/a> or 3104 aluminium coil<\/mark><\/a>, which offers the right balance of strength and flexibility. The lids use a slightly different alloy, often 5182<\/mark><\/a>, because they need to be stiffer.<\/p>\n\n\n\nStep 2: Blanking and cupping<\/strong><\/h3>\n\n\n\nThe aluminium sheet is fed into a cupping press. This machine punches out circular discs (called blanks) and immediately forms them into shallow cups.<\/p>\n\n\n\n
\n- Thousands of cups can be produced per minute<\/li>\n\n\n\n
- The process is very fast and highly automated<\/li>\n\n\n\n
- Scrap metal from the punched-out areas is collected and recycled on-site<\/li>\n<\/ul>\n\n\n\n
Step 3: Drawing and wall ironing (DWI)<\/strong><\/h3>\n\n\n\nThis is one of the most important steps. The shallow cup is pushed through a series of dies in a process called Drawing and Wall Ironing (DWI).<\/p>\n\n\n\n
Here’s what happens:<\/p>\n\n\n\n
\n- The cup is redrawn to reduce its diameter<\/li>\n\n\n\n
- It’s then ironed; pushed through rings that thin the walls while making the can taller<\/li>\n\n\n\n
- The base is shaped into a dome (this helps it withstand internal pressure)<\/li>\n<\/ul>\n\n\n\n
By the end of this step, the can has reached close to its final height and shape. The walls are extremely thin, but very strong.<\/p>\n\n\n\n
Step 4: Trimming<\/strong><\/h3>\n\n\n\nThe top edge of the can isn’t perfectly even after the DWI process. A trimmer cuts the top to make it uniform and level. The trimmed metal is recycled.<\/p>\n\n\n\n
Step 5: Washing and cleaning<\/strong><\/h3>\n\n\n\nThe can is washed thoroughly to remove:<\/p>\n\n\n\n
\n- Lubricants used during forming<\/li>\n\n\n\n
- Metal particles<\/li>\n\n\n\n
- Any surface contamination<\/li>\n<\/ul>\n\n\n\n
This is important for food safety and to help the coating and printing bond properly.<\/p>\n\n\n\n
Step 6: External coating and printing<\/strong><\/h3>\n\n\n\nOnce clean and dry, the outside of the can is coated with a base coat (usually white or clear). Then it’s printed using a dry offset printing process.<\/p>\n\n\n\n
\n- Up to 6 colours can be applied in one pass<\/li>\n\n\n\n
- The ink dries almost instantly using UV or thermal curing<\/li>\n\n\n\n
- A protective lacquer is applied on top to protect the print<\/li>\n<\/ul>\n\n\n\n
This is where branding, nutritional info, barcodes and design elements are added.<\/p>\n\n\n\n
Also read: Surface treatment guide for fabricators<\/mark><\/a><\/p>\n\n\n\nStep 7: Internal coating<\/strong><\/h3>\n\n\n\nThe inside of the can is spray-coated with a food-grade lacquer or epoxy lining. This coating:<\/p>\n\n\n\n
\n- Prevents the contents from reacting with the metal<\/li>\n\n\n\n
- Protects the aluminium from acidic or carbonated drinks<\/li>\n\n\n\n
- Keeps the taste and quality of the product intact<\/li>\n<\/ul>\n\n\n\n
The coating is then cured in an oven to harden it.<\/p>\n\n\n\n
Step 8: Necking and flanging<\/strong><\/h3>\n\n\n\nYou might have noticed that the top of the can is slightly narrower than the body. That shape is created in the necking stage.<\/p>\n\n\n\n
\n- The top is compressed inward in multiple steps to form the neck<\/li>\n\n\n\n
- A flange (a small outward lip) is then added at the very top<\/li>\n<\/ul>\n\n\n\n
The flange is what the lid seals onto later, once the can has been filled.<\/p>\n\n\n\n
Step 9: Quality inspection<\/strong><\/h3>\n\n\n\nBefore cans leave the factory, they go through strict checks:<\/p>\n\n\n\n
<\/a><\/figure>\n<\/div>\n\n\nStep 1: Sourcing and preparing the aluminium<\/strong><\/h3>\n\n\n\nIt all starts with aluminium alloy sheets. These are typically made from a mix of primary aluminium (from bauxite ore) and recycled aluminium. The sheets are rolled to a precise thickness, usually around 0.25 mm to 0.30 mm, at a rolling mill<\/mark><\/a>.<\/p>\n\n\n\nThe alloy used for can bodies is usually 3004 aluminium sheet<\/mark><\/a> or 3104 aluminium coil<\/mark><\/a>, which offers the right balance of strength and flexibility. The lids use a slightly different alloy, often 5182<\/mark><\/a>, because they need to be stiffer.<\/p>\n\n\n\nStep 2: Blanking and cupping<\/strong><\/h3>\n\n\n\nThe aluminium sheet is fed into a cupping press. This machine punches out circular discs (called blanks) and immediately forms them into shallow cups.<\/p>\n\n\n\n
\n- Thousands of cups can be produced per minute<\/li>\n\n\n\n
- The process is very fast and highly automated<\/li>\n\n\n\n
- Scrap metal from the punched-out areas is collected and recycled on-site<\/li>\n<\/ul>\n\n\n\n
Step 3: Drawing and wall ironing (DWI)<\/strong><\/h3>\n\n\n\nThis is one of the most important steps. The shallow cup is pushed through a series of dies in a process called Drawing and Wall Ironing (DWI).<\/p>\n\n\n\n
Here’s what happens:<\/p>\n\n\n\n
\n- The cup is redrawn to reduce its diameter<\/li>\n\n\n\n
- It’s then ironed; pushed through rings that thin the walls while making the can taller<\/li>\n\n\n\n
- The base is shaped into a dome (this helps it withstand internal pressure)<\/li>\n<\/ul>\n\n\n\n
By the end of this step, the can has reached close to its final height and shape. The walls are extremely thin, but very strong.<\/p>\n\n\n\n
Step 4: Trimming<\/strong><\/h3>\n\n\n\nThe top edge of the can isn’t perfectly even after the DWI process. A trimmer cuts the top to make it uniform and level. The trimmed metal is recycled.<\/p>\n\n\n\n
Step 5: Washing and cleaning<\/strong><\/h3>\n\n\n\nThe can is washed thoroughly to remove:<\/p>\n\n\n\n
\n- Lubricants used during forming<\/li>\n\n\n\n
- Metal particles<\/li>\n\n\n\n
- Any surface contamination<\/li>\n<\/ul>\n\n\n\n
This is important for food safety and to help the coating and printing bond properly.<\/p>\n\n\n\n
Step 6: External coating and printing<\/strong><\/h3>\n\n\n\nOnce clean and dry, the outside of the can is coated with a base coat (usually white or clear). Then it’s printed using a dry offset printing process.<\/p>\n\n\n\n
\n- Up to 6 colours can be applied in one pass<\/li>\n\n\n\n
- The ink dries almost instantly using UV or thermal curing<\/li>\n\n\n\n
- A protective lacquer is applied on top to protect the print<\/li>\n<\/ul>\n\n\n\n
This is where branding, nutritional info, barcodes and design elements are added.<\/p>\n\n\n\n
Also read: Surface treatment guide for fabricators<\/mark><\/a><\/p>\n\n\n\nStep 7: Internal coating<\/strong><\/h3>\n\n\n\nThe inside of the can is spray-coated with a food-grade lacquer or epoxy lining. This coating:<\/p>\n\n\n\n
\n- Prevents the contents from reacting with the metal<\/li>\n\n\n\n
- Protects the aluminium from acidic or carbonated drinks<\/li>\n\n\n\n
- Keeps the taste and quality of the product intact<\/li>\n<\/ul>\n\n\n\n
The coating is then cured in an oven to harden it.<\/p>\n\n\n\n
Step 8: Necking and flanging<\/strong><\/h3>\n\n\n\nYou might have noticed that the top of the can is slightly narrower than the body. That shape is created in the necking stage.<\/p>\n\n\n\n
\n- The top is compressed inward in multiple steps to form the neck<\/li>\n\n\n\n
- A flange (a small outward lip) is then added at the very top<\/li>\n<\/ul>\n\n\n\n
The flange is what the lid seals onto later, once the can has been filled.<\/p>\n\n\n\n
Step 9: Quality inspection<\/strong><\/h3>\n\n\n\nBefore cans leave the factory, they go through strict checks:<\/p>\n\n\n\n
The alloy used for can bodies is usually 3004 aluminium sheet<\/mark><\/a> or 3104 aluminium coil<\/mark><\/a>, which offers the right balance of strength and flexibility. The lids use a slightly different alloy, often 5182<\/mark><\/a>, because they need to be stiffer.<\/p>\n\n\n\n The aluminium sheet is fed into a cupping press. This machine punches out circular discs (called blanks) and immediately forms them into shallow cups.<\/p>\n\n\n\n This is one of the most important steps. The shallow cup is pushed through a series of dies in a process called Drawing and Wall Ironing (DWI).<\/p>\n\n\n\n Here’s what happens:<\/p>\n\n\n\n By the end of this step, the can has reached close to its final height and shape. The walls are extremely thin, but very strong.<\/p>\n\n\n\n The top edge of the can isn’t perfectly even after the DWI process. A trimmer cuts the top to make it uniform and level. The trimmed metal is recycled.<\/p>\n\n\n\n The can is washed thoroughly to remove:<\/p>\n\n\n\n This is important for food safety and to help the coating and printing bond properly.<\/p>\n\n\n\n Once clean and dry, the outside of the can is coated with a base coat (usually white or clear). Then it’s printed using a dry offset printing process.<\/p>\n\n\n\n This is where branding, nutritional info, barcodes and design elements are added.<\/p>\n\n\n\n Also read: Surface treatment guide for fabricators<\/mark><\/a><\/p>\n\n\n\n The inside of the can is spray-coated with a food-grade lacquer or epoxy lining. This coating:<\/p>\n\n\n\n The coating is then cured in an oven to harden it.<\/p>\n\n\n\n You might have noticed that the top of the can is slightly narrower than the body. That shape is created in the necking stage.<\/p>\n\n\n\n The flange is what the lid seals onto later, once the can has been filled.<\/p>\n\n\n\n Before cans leave the factory, they go through strict checks:<\/p>\n\n\n\nStep 2: Blanking and cupping<\/strong><\/h3>\n\n\n\n
\n
Step 3: Drawing and wall ironing (DWI)<\/strong><\/h3>\n\n\n\n
\n
Step 4: Trimming<\/strong><\/h3>\n\n\n\n
Step 5: Washing and cleaning<\/strong><\/h3>\n\n\n\n
\n
Step 6: External coating and printing<\/strong><\/h3>\n\n\n\n
\n
Step 7: Internal coating<\/strong><\/h3>\n\n\n\n
\n
Step 8: Necking and flanging<\/strong><\/h3>\n\n\n\n
\n
Step 9: Quality inspection<\/strong><\/h3>\n\n\n\n
![\"Aluminium](\"https:\/\/www.alcircle.com\/blog\/wp-content\/uploads\/2026\/05\/Aluminum-Can-Lid-Manufacturing-1-1024x683.png\")
<\/a><\/figure>\n<\/div>\n\n\n