Beverage can: What you need to know before manufacturing

The world’s consumption uses about 180 billion beverage cans every year.

Till today, cans are one of the most favored containers for people to enjoy their beloved drinks. Refreshing look and touch, easy to grab and hold anytime, anywhere, especially environmental-friendly, these cans are not the only reason you are going to be one of the leading beverage companies. Still, it plays an essential role in it.

This article will help you get a clearer view of what things are like in manufacturing a beverage can:

• What it made of?
• How exactly do they form a beverage can?
• Why do both customers and beverage owners so favor these cans?
• What needs to know before manufacturing a beverage can?

First, let get to know the basic:

Structure of an aluminum beverage can

A standard beverage can is made up of two sections that arrive empty and separately to a canning company: the can body and the can end (or lid).

Can bodies are typically constructed from a single piece of aluminum or steel drawn into a cup, punched, and ironed into a simple can body. The can body is then necked, which means that the top portion is trimmed to a smaller diameter.

Can ends (also known as lids) of beverage cans are always made of aluminum alloy and pressed from a slightly more substantial and thicker mix of aluminum than the can body. And the pull tabs on the can ends are pressed on separately.

Although all beverage cans now have two pieces (body and end), this was not always the case. Drink cans used to be made up of three components: a top (end), a bottom, and a rolled and soldered or welded cylinder.

The inner lining of an aluminum beverage can

Almost all food and beverage products packaged in metal cans have an inner lining made primarily of BPA (Bisphenol A). This coating offers a strong defence against interactions between beverages and aluminum.

The inner lining of an aluminum beverage can plays a crucial role in maintaining its quality and safety.

• • Since aluminum can react with some liquids, especially acidic ones, it avoids direct contact between the beverage and the aluminum.
  • The lining keeps the drink’s flavor, freshness, and fizziness intact.
  • It guarantees that drinking the beverage will not become dangerous.

The lining is applied to the inside surface of the aluminum can during manufacturing. Usually, it is a very thin layer, only a few microns thick, to reduce any effect on the can’s total weight.

On the other hand, some cans employ coatings made of polymers rather than epoxy. These coatings are also food-safe and prevent flavor transfer.

The material used to make aluminum beverage cans

Naturally, the can body is mainly made from aluminum or tin-plated steel (also known as tinplate). The ore known as bauxite is the source of aluminum. After being cleaned, bauxite is melted, and the molten metal will be used to make the aluminum sheet for the can body.

With the can end, it is usually made from a combination of aluminum and other materials, such as silicon, copper, iron, manganese, and magnesium.

In the United States, the can is most often made almost entirely of aluminum. Still, drink cans made in Asia and Europe are approximately 45 percent aluminum and 55 percent steel.

Aluminum beverage can sizes

Aluminum beverage cans come in different sizes, each intended to hold a particular volume of liquid. Let’s explore some common sizes:

Remember, these dimensions may vary slightly based on specific brands and regions.

The design of an aluminum can

An aluminum beverage can’s design is a fantastic fusion of engineering, usability, and branding. To help you better understand aluminum can designs, here are some frequently asked questions about them.

The design of an aluminum can is full of engineering wonders

Why is aluminum can cylinder-shaped?

Aluminum beverage cans’ cylinder shape serves multiple important purposes:

• • The cylinder cans could be manufactured using less material, but still have robust strength. Can manufacturers will save on material costs but still maintain maximum durability.
  • Cylindrical cans are easier to stack and store than other shapes, maximizing warehouse/container occupancy during transportation and storage.
  • The shape can be rapidly manufactured using fewer steps and machines than spheres or cuboids.

So, while the cylinder shape might seem simple, it combines functionality, and practicality.

Why is the aluminum can’s bottom domed inward?

The curved bottom of an aluminum can evenly distribute internal pressure onto the can’s wall. The can will be able to handle more pressure and can’t burst easily. This is especially useful to contain carbonated soda.

This significantly increases the beverage can’s strength and integrity during transport. In addition, it also means the cans can be made thinner using less aluminum. This can significantly reduce the manufacturer’s material costs.

Why do beverage cans have tapered necks?

Tapered necks on beverage cans have a smaller diameter and reduce material costs. The tapering means manufacturers can use a smaller lid, the most  expensive component of the can.

The tapered necks also let the beverage cans stack nicely, allowing for more efficient storage and transportation. They fit together like puzzle pieces, which reduces wasted space.

Aluminum beverage can manufacturing process

The production process for aluminum beverage cans involves several intricate procedures to guarantee effectiveness, consistency, and quality. Every process step, from designing and printing to attaching the lid to shaping aluminium cups, calls for exact engineering and stringent quality control.

Typically, the aluminum can production process includes two main processes: the can body and the can end. These two parts will then be joined once the drink is filled.

Can Body Manufacturing

Step 1. Uncoiling and Lubrication: The process begins with inserting an aluminum coil into an uncoiler and applying food-grade lubricant to the aluminum sheet.

Step 2. Molding: A cupper press machine cuts and molds the sheet into cylinders. Aluminum scrap is recycled.

Step 3. Stretching and Shaping: Molded cylinders are stretched to the desired height and thickness. The base is dome-shaped and the top flattened for strength and pressure resistance.

Step 4. Cleaning: Chemicals, water, and reverse osmosis water are used to clean and sanitize the cans. A food-grade lubricant is applied before bake drying.

Step 5. Printing: The cans are printed in up to six colors in a 360-degree seamless design. A color coating protects against scratches before baking.

Step 6. Necking: The top of the can is shortened to attach the lid during the beverage manufacturing process.

Step 7. Leak Testing and Packing: All cans are inspected for leaks with a special light. Leak-free cans are packed for transport to the beverage filling facility.

Can Lid Manufacturing

Step 1. Uncoiling and Lubrication: An aluminum coil is put into an uncoiler and lubricated, just like the can body.

Step 2. Shell Pressing: The metal sheet is stretched a little and cut into circles. For a solid fit, the can end is glued to the body and checked for damage before it is baked to dry.

Step 3. Pull Tab Production: The lid is scored, and a pull tab is added to facilitate opening.

Step 4. Leak Testing and Packing: The can ends are also checked for leakage. Leak-free can ends are put in boxes, ready to be sent.

Assembly

The can end and body are sent separately to the beverage filling facility. After the can is filled, the can seamer machine uses an overlapping technique to securely join the two halves together.

Aluminum cans manufacturing process

What are the advantages of aluminum cans for beverage?

Taste: Cans protect product integrity

Aluminum cans help to preserve the quality of drinks for a long time. Aluminum cans are completely impervious to oxygen, sun, moisture, and other contaminants. They don’t rust, are corrosion-resistant, and have one of the longest shelf lives of any packaging.

Sustainability: Cans are better for the planet

Today, aluminum cans are the most recycled beverage container since they are the most valuable box in the bin. 70% of the metal in an average can is recycled. It can be recycled time and time again in a true closed-loop recycling process, while glass and plastic are usually down-cycled into items like carpet fiber or landfill liners.

Innovation: Cans enhance brands

Can showcase brands with a unique, wrap-around canvas. With a full 360˚ of printing space, can maximize the branding opportunity, capturing attention and driving consumer interest. 72% of consumers say cans are the best packaging for delivering excellent graphics vs. only 16% for glass bottles and 12% for plastic bottles.

Performance: Cans are better for the refreshment on the go

Beverage cans are prized for their portability and convenience. Durable, and lightweight, they chill faster and are a perfect match for active lifestyles without the possibility of accidental breakage. Cans are also ideal for use in outdoor venues where glass bottles are prohibited, such as arenas, festivals, and sporting events, enabling consumers to enjoy their favorite beverages whenever and wherever they choose.

Consumers surveyed preferred cans, according to the Can Manufacturers Institute, because they:

• • Feel cooler and more refreshing – 69%
  • Are easy to grab on the go – 68%
  • Are easier to carry and less likely to be damaged than other packages. – 67%
  • Provide a fast recharging and refreshing alternative – 57%

Shipping efficiency: the weight advantage

Aluminum cans are light and can be stacked easily. This reduces storage and shipping costs while also lowering overall transportation carbon emissions through logistics and supply chains.

4 key notes before manufacturing beverage can

Note 1: Lead time can be long and fluctuate throughout the years

One of the most critical aspects of your beverage business is lead times. Inadequate lead times can throw your entire production and launch schedule off, as well as drive up your costs. When lead times fluctuate during the year, as they often do, the choices are restricted due to the shortlist of can suppliers.

In some cases, a typical 6-8 weeks lead time can stretch to 16 weeks within a short period. Although lead times are incredibly long during the summer months (also known as “beverage season”), new packaging trends or huge orders may extend lead times even further.

Keep track of your plans and, if possible, keep an additional month’s worth of inventory on hand, particularly during the spring and summer months, to mitigate the effect of unforeseen lead times on your production timeline.

Maintaining open lines of communication with your supplier is essential. When you provide your can supplier with frequent updates on your forecasted demand, you allow them to notify you of any changes that may affect product availability.

Note 2: MOQ (minimum order quantities) are higher than you think

For printed cans, most suppliers require a minimum order of a truckload. Full truckload (FTL) varies depending on the size of the can. For example, The MOQ for a 12-oz/355ml regular beverage can in American canning is 7002 cans/pallet.

If you can’t meet the requirement for a minimum order, you can order pallets of brite cans from a broker or reseller and get them sleeved. Can sleeves are shrink-wrapped labels that are digitally printed and adhered to the can’s surface. While this method helps you to produce smaller quantities of cans, it’s essential to keep in mind that the per-unit cost is typically a bit higher than with printed cans.

Short runs are usually more expensive, and if you don’t hit the minimum, you could have to pay extra for sleeving. Considering all of this data would allow you to be more practical when calculating and preparing the cost and quantity of your orders.

Note 3: There will be differences between the color on your design file and your cans

Your beverage brand is an important asset that you want to plan and manage through your ads and packaging carefully. Although most people and designers are familiar with traditional 4-color process printing, printing on cans is very different. In the 4-color process printing, four colors (black, yellow, magenta, cyan) are added as separate layers to a substrate. Additional colors are produced by overlapping those colors or inserting a spot color or PMS color.

All of these colors must be transferred to the can simultaneously from a single common plate while printing. Since the can printing process does not allow for color mixing, you are limited to six spot colors. Color matching on cans can be complex, particularly with white hues.

So before you start the printing process, you should contact and check with printers. This will have you in creating and adjusting your beverage packaging design. Check out more steps to create a packaging design here.

Since can printing requires so much specialized expertise, it’s crucial to work closely with vendors who specialize in can artwork and unique requirements before placing an order. It’s also a good idea to attend the color proofing and press check to ensure that the printed cans are just as you imagined before full production begins.

Note 4: Your liquid must be tested before can-filling

Before being packaged into cans, all liquids must be tested for corrosion. This testing will decide the type of can lining required for your beverage, as well as how long it will last. Before producing your finished drink, can manufacturers and most contract packers require that you have a can warranty.

A few things that can cause your beverage to be corrosive include alcohol, juice, sugar concentration, acidity level, chlorides, coloring additives, copper, CO2 volume, and preservation methods.

Most corrosion tests result in a 6 to 12-month warranty. Some drinks are too corrosive to be sold in aluminum containers, so keep that in mind. Testing properly ahead of time will help you save time and money.

List of global aluminum can suppliers

The global aluminum can market is dominated by several large suppliers who provide beverage manufacturers worldwide with premium cans. Among the well-known providers are:

Ball Corporation

Ball Corporation is the world’s foremost supplier of inventive, eco-friendly aluminum packaging for household goods, beverages, personal hygiene products, and other technologies and services.

The company has a rich history, dating back to 1880 when the Ball brothers borrowed money to acquire the Wooden Jacket Can Company. Since then, Ball has been at the forefront of packaging solutions, including glass jars and lids for home canning.

Crown Holdings, Inc

Crown Holdings, Inc. is a leading supplier of beverage packaging, food packaging, aerosol packaging, metal closures, promotional, and transit packaging products. Their headquarters are located in Philadelphia, Pennsylvania. They contribute significantly to the supply of creative and environmentally friendly packaging solutions to various industries.

Amcor Plc

Amcor Plc is a global packaging company that develops and produces various packaging solutions. They are experts in providing services and products for multiple industries, including food, beverage, pharmaceutical, medical device, home and personal care, and others. They also specialize in flexible packaging, rigid containers, speciality cartons, and closures.

Ardagh Group S.A.

Ardagh Group S.A. provides brand owners worldwide with environmentally friendly, infinitely recyclable glass and metal packaging. Their expertise lies in developing packaging solutions that integrate industry-leading innovation, superior quality, and attentive customer service.

With operations in 16 countries and approximately 20,000 employees, Ardagh produces metal and glass containers for various sectors, including beer, food, wine, spirits, soft drinks, energy drinks, and more.

CMPC Holdings Limited

CMPC Holdings Limited is a manufacturer of packaging products, including aluminum cans. They are part of the CPMC Group, one of the core business divisions under COFCO Group (a Fortune 500 company and their controlling shareholder).

CMPC Holdings manufactures a wide range of packaging options for consumer goods, catering to several industries, including industrial goods, pharmaceuticals, food and drink, cosmetics, and household goods. Their aluminum aerosol cans find applications in cosmetic, food, beverage, and pharmaceutical products.

These businesses are renowned for their dedication to sustainability, innovation, and high quality in producing aluminum cans.

Conclusion

Aluminum cans are a superior packaging type when it comes to making a perfect soft drink. Every beverage company develops products using aluminum beverage cans thanks to their durability, recyclability and quality preservation.

Tan Do is a beverage manufacturer/suppliers, offering a variety of sizes and formulations to meet diverse market needs. Our commitment to innovation and quality will ensure your products stand strong in the beverage market.

Contact us today to let Tan Do help you realize your vision.

Tan Do is a global beverage ODM/OEM manufacturer and supplier located in Vietnam. Since 1996, we have built trust and credibility not only throughout Vietnam but also in many parts of the world. Leveraging state-of-the-art technology, we have crafted thousands of products that align with ISO, HACCP, HALAL, FDA, and many other standards.