Aluminium can industry focuses on circularity, lightweighting, and packaging innovation

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Aluminium can manufacturers are introducing new designs and technologies to improve sustainability, production efficiency and consumer convenience. Companies including Canovation, Henkel Adhesive Technologies and Sonoco say the industry is focusing on circularity, lightweighting, resealable packaging, water-based sealants and digital manufacturing tools to meet changing market needs.

Jeff Grajewski, Chief Operations Officer at Canovation, said the next generation of aluminium can innovation is being shaped by sustainability, cost, health and safety regulations, branding, and consumer experience. He noted that while sustainability remains important, new packaging solutions also need to provide a clear economic benefit, comply with regulations and offer added value to both brands and consumers.

Rut Jordana, Business Development Manager for EIMEA Metal Packaging at Henkel, said circularity, lightweighting and high-speed production are among the main trends in aluminium packaging. She said, “Aluminium cans are increasingly chosen for their recyclability and low carbon footprint, while brand owners demand lighter designs without compromising performance.” At the same time, brands are looking for lighter cans, more varied shapes and sizes, and improved visual appeal, which is making production more complex.

Balancing lightweight with performance

Jordana said manufacturers continue to face challenges in reducing can weight while maintaining strength, durability, food safety and long shelf life. She added that seal integrity, corrosion protection and compatibility with different food and beverage products remain important technical requirements.

She also pointed out that aluminium can be recycled repeatedly and can return to the market as a new product in as little as 60 days. According to Jordana, the upcoming EU Packaging and Packaging Waste Regulation (PPWR) is expected to further support aluminium recycling across Europe.

Francesco Giannolo, Vice President for Commercial at Sonoco Consumer Packaging EMEA and APAC, said brands are increasingly using aluminium packaging to offer premium designs and convenient portion sizes. He highlighted Sonoco's collaboration with Fábrica de Conservas da Murtosa, where high-quality printing, embossing and debossing were used to create a premium aluminium sardine tin.

Sonoco is also seeing growing demand for 85g aluminium cans for wet pet food. Giannolo said aluminium's barrier properties, recyclability and established recycling infrastructure make it a suitable option as brands look for more circular packaging. He added, “The 85 g format also aligns with consumer demand for convenient portion sizes that help minimise food waste. Sonoco invested in metal packaging for wet pet food with the opening of a new line in Outreau, France.” 

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Resealable cans and water-based sealants

Canovation is developing CanReseal, an all-metal resealable aluminium can designed to improve convenience while maintaining recyclability. The company said the design combines resealability, a single-alloy structure, compatibility with existing manufacturing systems and new branding opportunities.

Daniel A. Zabaleta, Chief Technology Officer at Canovation, said CanReseal provides a wide drinking opening together with a twist-on and twist-off closure that helps keep beverages fresh, prevents spills and improves portability. He added that the design uses existing can manufacturing infrastructure instead of requiring a completely new production system.

Henkel has introduced Darex WBC 4020, a new water-based sealant for beverage cans, with a single global formulation manufactured using locally sourced raw materials to reduce supply chain risks. The company is also introducing Darex WBC 833 for food cans in the EIMEA region, which is designed to improve productivity while maintaining performance in different food environments.

Henkel said it is also expanding its range of safer can sealants, including an allergen-free version of WBC 9000 in North America and Darex COV sealants in EIMEA that are free from phthalate-based plasticisers and help reduce energy use and carbon emissions.

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Digital technologies improve can manufacturing

Both Henkel and Canovation said new technologies are helping improve aluminium can manufacturing. Henkel's Bonderite C-IC 72000 cleaning system operates at lower temperatures than conventional systems, reducing energy consumption and carbon emissions while improving production stability. The company also uses digital monitoring and process control tools through its Bonderite E-CO equipment and CanLine audit application. Jordana said, “They support continuous improvement, failure detection, and proactive, preventive maintenance.” 

Canovation said the design of CanReseal is based on a redesigned aluminium can end consisting of a threaded ring and matching closure. Grajewski said, “In many ways, technological advancements have already helped Canovation’s CanReseal, as it is based on decades of industry investments in high-speed and efficient can manufacturing and filling infrastructure.”