Orora’s Helio direct-to-can digital printing technology has been used on aluminium cans  for Pirate Life Brewing’s latest limited-edition release, Mosaic Discotheque, highlighting its ability to create high-build, tactile finishes on aluminium packaging.

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The project is part of a wider set of Helio-based applications, reflecting its use in short-run, design-focused aluminium can production.Developed to mark Pirate Life’s 11th anniversary, the 500ml aluminium can carries a disco ball-style design created by layering gloss and matte spot varnishes over a white-to-grey gradient.

This effect comes from Helio’s high-build coating process, where a specialised coating is applied through a dedicated print unit and then UV-cured on the aluminium surface. The method allows thicker ink layers to be applied, resulting in a raised, dimensional finish. The surface appears textured and reflective, something not easily achieved using conventional can decoration techniques.

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David Muzeen, pre-press supervisor at Orora’s Decoration Centre of Excellence, said “Pirate Life involved us at the concept stage so we could optimise the artwork for Helio and achieve the mirror ball effect. We produced sample cans, refined the finish, and quickly iterated based on feedback.”

The digital workflow made it possible to adjust files and re-sample quickly, helping to shorten lead times and support more flexible aluminium can production. It also allows designs to be tested and refined without the limitations of traditional printing methods, including lower minimum order quantities and shorter turnaround times.

Pirate Life’s head of marketing, Bianca Roworth added, “We wanted to level up the packaging for this release, and Helio allowed us to achieve a vivid, reflective finish that enhances the design.”

As digital decoration technologies continue to develop, Helio is being used in short-run aluminium can applications where both detailed design and production flexibility are required.

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