Background
Aluminum cans are the most preferred packaging for many drinks, both at home and on-the-go. The benefits include its exceptional performance, high speed of filling, excellent presentation of brands, and long shelf life, as well as reduced damages throughout the distribution channels (“The Beverage Can”). Hence, the literature review will cover the design and manufacturing process of aluminum cans, the advantages over other packaging materials, the primary and secondary manufacturing process, the recycling process, and the market share of aluminum cans.
Aluminum cans are cylindrical, used to hold a single serving of drink for single use. Structurally, the aluminum can is made of three main parts; “the walls and the bottom, which are made from a 3000-series alloy, the top made from 5000 -series alloy punched out a circle and a pull tab of 5000-series alloy” (“Closing the loop: Design for Recovery Guideline: Aluminum Packaging” 8). During the manufacturing process, the body of the can is made first, while the top and the pull tab are fixed later after the beverage is filled.
The majority of soft drink and beer cans within the United States are made from aluminum. It was estimated that the United States makes approximately 100 billion cans a year, which sums up to at least one can daily for every American (“Closing the loop: Design for Recovery Guideline: Aluminum Packaging” 8). The unique properties of aluminum make it ideal in the storage of carbonated beverages. Although aluminum is light, its walls can stand a pressure of above 90 pounds per square inch when pressed by carbon dioxide inside the soft drinks or beer (“Closing the loop: Design for Recovery Guideline: Aluminum Packaging” 8). In addition, the physical appeal of aluminum cans is essential in grabbing consumers’ attention in the market, which is quite competitive.
(Picture: aluminum can)
History of Aluminum Cans
Aluminum metal was discovered around 1782. In1850, it was termed to be more prestigious than gold in France, for making jewelry and utensils. Napoleon III financed experiments concerning aluminum extraction since he was fascinated by its lightweight properties for military uses (Woodward). Due to the elusiveness of the extraction process, the metal remained highly-priced, and only a little of it was used commercially. However, there was a technological breakthrough in the 19th century, which assisted the smelting of aluminum cheaply (Woodward). Hence, the prices of aluminum reduced significantly.
Aluminum was used for beverage storage in World War II, primarily to ship beer to servicemembers overseas. Adolph Coors Company made aluminum cans, which were used for beer storage in 1958 (Woodward). The aluminum can was a two-piece container and could only hold 7ounces of beer instead of 12 ounces. The model that followed was made of steel with aluminum top, where the aluminum end changed the reaction between steel and the beer; hence, increasing the shelf life of beer (Woodward). By 1968, the majority of beer storage in the United States used this particular can.
In the 1960s, aluminum was used for frozen juice concentrate. A study conducted by the Reynolds metal company showed that in 1961, people had a preference of aluminum cans over cans made of tin-plated steel. Hence, aluminum cans that had easy to open lids were introduced in the market (Pinkyam). By 1963, beverage cans were produced in large quantities, and in 1967, production swelled after both Pepsi and Coca-Cola started using aluminum cans. In the 1990s, the demand growth of aluminum cans declined in the market, with plastics putting pressure on the soft drinks segment and an increase in market share of glass due to increased popularity of microbreweries. Later, can makers adopted improved technology of lightweight cans using light gauge sheet, to gain competitiveness among other beverage packaging (Pinkyam). In the last ten years, aluminum can makers and sheet producers have gone through a considerable consolidation effort, which has enhanced their capacity in the market. For instance, the aluminum can rolling mills in the United States have reduced from 11 to 4, among them Alcoa and Alcan, the two account for three-quarter of the stock in the world (Pinkyam). However, can-making companies have reduced since major brewers prefer making their packaging cans.
Raw Materials and Processing
The primary raw material for Aluminum cans is aluminum metal, which comes from bauxite ores, specifically boehmite, gibbsite, and diaspora. Bauxite used in the United States is imported from Guinea and Jamaica (“The Aluminum Page”). The aluminum properties are customized for various applications by mixing it with elements, such as manganese, zinc, copper, silicon, and magnesium. Since various applications require different characteristic performance, different aluminum alloys, which have various material properties combinations, such as formability, ductility, and strength are available (“Closing the loop: Design for Recovery Guideline: Aluminum Packaging” 6). There are three main alloy types, 1000-series, 5000-series, and 3000-series. The 3000-series is the most widely used type of alloy among aluminum packaging that is recycled. In this series, manganese is the main alloy element. The second commonly used is the 5000-series, which contains magnesium to enhance hardness, which is widely used for can lids, while the 1000-series is aluminum of high purity and contains less than 1% alloying elements (“Closing the loop: Design for Recovery Guideline: Aluminum Packaging” 6). Notably, this alloy is used to make aluminum foil packaging.
Before mining of these ores, the land is cleared and deforested, and then seeds and saplings are collected to ensure that land is re-vegetated after depletion of bauxite. After it is imported, bauxite goes through the Bayer process for the extraction of aluminum (“The aluminum page”). The Bayer process was patented and invented by Joseph Bayer in 1887. This process is the main method for the extraction of alumina, also known as aluminum oxide. After washing of Bauxite, it passes through screens for crushing to ensure that ore particles are of one size. It is then put in grinding mills that have caustic soda, lime, and sodium hydroxide, which come from the Bayer process’ precipitation stage. It is then mixed in extreme pressure and temperature to produce a slurry, which contains sodium aluminate and undissolved residues of bauxite, iron oxide in high concentrations, silicon oxide, and titanium oxide (“The aluminum page”). The byproduct is known as the red mud. This slurry is them moved to a digester, and more caustic mixture added to dissolve sodium aluminate at high temperatures, and both undissolved and undesired residues are cleaned out. The bauxite is then heated at 200 degrees or 145 degrees, to ensure sodium aluminate dissolves, and then cooled at 106 degrees to reduce temperature and pressure. It forms steam, which preheats the slurry and saves the usage of energy (“The aluminum page”). This solution is taken to settling tanks, where the slurry solution separates from caustic soda and sodium aluminate concentrate.
The red mud is then moved to tanks for washing to save more caustic soda, after which it is extracted as a byproduct waste of the Bayer process. The concentrate is processed through several filters to extract undissolved bauxite residue that remains from the concentrate then it is pumped in precipitators. Small particles of alumina, which are known as alumina hydrate, are added in the precipitation as it cools (“The aluminum page”). After alumina crystals settle on the tank’s bottom, it is filtered to remove impurities and moisture before transferring in calcining kilns. The crystals are then heated in high temperatures of 1100 degrees as it is rotated to remove more moisture before cooling down. This results in pure alumina in white powder form (“The Aluminum Page”). The product is then shipped for further processing, including smelting into a metal.
To turn alumina to metallic aluminum, the powder goes through a process called Hall-Heroult. In this process, the alumina is mixed with molten Crolite, sodium aluminum fluoride, and oxygen. Direct Electrical Current is then run to produce carbon dioxide and metallic aluminum (“Karen”). To this product, small amounts of metals like magnesium are added to strengthen the metal as well as prevent corrosion before being cast into ingots, which are rolled in sheets and later coiled (“Karen”). The final product is then shipped to cans manufacturing plants.
When the aluminum coils reach the plants, they are unrolled and lubricated to ensure the aluminum flows smoothly through the formation of a can. The aluminum sheet is put in cupping press to cut out shallow cups, and then drawn in a cup and ironed for thickness. The tops are trimmed to achieve equal height and width, and any punctured aluminum is removed for recycling. The cans are cleaned, rinsed, dried, and inked. Later, cans are taken through a rubber cylinder, which prints about eight colors on the can at the same time (“How Are Aluminum Cans Made?”). The spinning and vanishing processes are done to protect the paint. The paint is then secured by baking them in an oven, and a protective coat is sprayed on the inside to protect the beverage from contamination. The neck of the can is then narrowed to prepare it for sealing, while the bottom is domed to create the strength needed for the internal pressure. All aluminum cans are taken through a light tester to detect holes to ensure that there are no leaks. They are then palletized and shipped to respective beverage companies (“How Are Aluminum Cans Made?”). Finally, the companies receive and fill them with drinks.
Aluminum Can Recycling and Secondary Processing
Aluminum as a packaging material is highly recycled to offer both environmental and economic benefits. For instance, in 2008, a total of 1.88 million tons of aluminum packaging was utilized and discarded, where 41.5% of it was recovered. However, it is notable that the value of used aluminum cans has been fluctuating. For instance, in 2007, ninety percent of the discarded aluminum was recovered (“Closing the loop: Design for Recovery Guideline: Aluminum Packaging” 7). This has been made possible because different States have legislation for container deposits to regulate the collection and recycle of aluminum beverage cans.
Recycling of aluminum saves 95% energy used in producing a primary metal. Notably, ecycling uses only 5% energy to make secondary metal in comparison to primary metal, hence generating only 5% emissions of greenhouse gas. When a kilogram of aluminum is recycled, it saves 8 kilos of bauxite, 14 kilowatts of electricity, and 4 kilos of chemical (Kiffaya and Layla 160). More so, recycling aluminum reduces the volume of landfills. Aluminum cans are the highest recycled packaging material, due to the scrap metal high value. For instance, twenty aluminum cans are recycled using the same energy used in producing a single new can (Kiffaya and Layla 160). The recycling of aluminum cans is a successful and profitable industry.
Remelting aluminum scrap uses 5% energy required in primary aluminum processing from bauxite. After recovery, the scrap metal from extrusions, forgings, and fabricating sheet is taken back to the furnace. The scrap produced from the fabrication of aluminum is collected by businessmen who run the secondary aluminum processing industry. The composition of new scrap is well defined and sold to primary aluminum processors to make a new alloy. The new scrap is usually supplemented by the old one, which was recycled from discarded cans (Kiffaya and Layla 159). Since the old scrap is usually dirty and contains several alloys, it is put in casting alloys that contain high alloy elements (Kiffaya and Layla 159). Therefore, recycled aluminum cans are used in making new stock of the product
Sustainability
The aluminum cans have high sustainability credentials since aluminum and steel are not depleting resources (“The Aluminum Can Advantage”). Aluminum is ranked as the third most abundant metal, while iron is the fourth. However, steel is the most recycled material in the world. Hence, in a year, below 150,000 tones of metal are utilized in making 9 billion cans, which is a small fraction. The majority of environmental impacts of aluminum cans, such as emissions, energy use, carbon, wastes, and effluents, are related to the metal supply (“The Aluminum Can Advantage”). Hence, the metal industry has put effort to reduce environmental impacts. The aluminum cans manufacturing industries have also put investments that have created significant improvements in its sustainability and environmental performance, focusing on improved energy and efficient use of water. Further investments have ensured that the walls of the cans are thinner (“The Aluminum Can Advantage”). Hence, the can is lighter and uses less metal while still improving and maintaining the can’s robustness.
Aluminum cans are regarded as the most sustainable package for beverages in all measures. The aspect involves recycling rates, stackability, lightweight, and strength. Besides, the metal allows various brands to transport and package using less material for more beverages. Aluminum cans are more valuable than plastic and glass, hence making municipal recycling financially viable and effective in subsidizing recycling.
(“The Aluminum Can Advantage”)
Almost all aluminum cans undergo recycling severally in a closed-loop, while plastics and glass are down-cycled to make products, such as fiber, carpet, and liners for landfills. Therefore, aluminum cans usually support the municipal recycling program. These programs depend on selling recycled materials. The high aluminum value within the recycling stream ensures effective subsidization of recycling. The report shows that scrap from aluminum cans is worth $1,317 ton while that of plastic and glass is worth $299 and $-20, respectively (“The Aluminum Can Advantage”). On the other hand, it has been found out that the greenhouse gas emissions that are associated with refrigeration and transportation of beverages in aluminum cans are much lower compared to plastic and glass under the same conditions. The findings revealed that emissions related to cooling and transporting aluminum cans on per liter basis were 21% lower as compared to plastic bottles and 49% lower in comparison to glass bottles (“The Aluminum Can Advantage”). Notably, amidst all the sustainability advantages, there is an opportunity for improvement, since, in 2018, it was noted that 45.2 billion aluminum cans ended in landfills, which is a loss to the environment and the economy. Besides, it was revealed that the energy that could be saved by recycling 100% of the cans was enough to power 4.1 million houses annually (“The Aluminum Can Advantage”). Therefore, the difference is considered an economic and environmental loss.
Aluminum can Market Share
Currently, aluminum cans have half of the single service market and around 85% of the multipack market for soft drinks. For the alcoholic market, the mix of both multipacks and single-serve is 50%: 50% between cans and glass. However, there is hope since some bottled water is using smaller volume cans for packaging. Besides, specialty drinks, such as energy drinks, use aluminum cans though in smaller ounces of 8.2 ounces (Pinkyam). The Japanese have made aluminum bottle, which has been known as the “bottle can.” Consumers have embraced this invention due to its resealability, which makes it superior to aluminum can (Pinkyam). Notably, an aluminum bottle that was three-piece instead of two-piece was considered earlier by the Crown.
As a form of marketing push, the aluminum association has used approximately $75 million in the last six years in advertising on television, to create awareness to consumers about aluminum can features. The main selling point has been fizz and chill, in that the aluminum can chill beverages faster than any other packaging, while it is efficient in maintaining fizz until opened (Pinkyam). Other selling points of the aluminum cans are based on cost, stackability, speed of filling, fair space usage, and the ability to put up an advertisement on the can. The cans hold recycled content that is more than 51% (Pinkyam), in comparison to any other beverage packaging material.
Aluminum cans-making companies, such as Alcan, has supported innovation by Applied Materials in Illinois and Research and development center in Ontario. The Applied Material Center resolves daily issues in manufacturing and allows accurate and quick results from new designs and modifications made in the cans-making process (Pinkyam). In Ontario, Alcan has tapped engineers, element analysts, and scientists to come together in simulating the process of making cans using computers. They create virtual can line and identify locations and hot spots for potential failure and hasten the process of prototyping for can design evolution. The aluminum cans give room for innovation (Pinkyam). For instance, Crown launched a “super end” beverage can, which has been the leading innovator in an aluminum can manufacturing. This innovation has improved performance and quality for consumers and beverage fillers who use the cans. The new design uses 10% less metal and offers increased drinkability and pourability (Pinkyam). In addition, the pull-tab is set at a higher angle to make opening easier, especially for the elderly and children. Another innovation is the shape of the aluminum cans, which allows the customization of shapes (Pinkyam), like Heineken beer, which bears keg shape.
Conclusion
The aluminum can has gone through a long evolution since its introduction. The can remains the most preferred packaging for beverages because of various characteristics, including stackability, maintenance of fizz and chill, pourability, light in weight, ease of advertising through the can, among others. Aluminum remains the most recyclable material for beverage cans compared to plastic and glass, giving aluminum a considerable advantage concerning environment and economy benefits. The aluminum cans hold a high market share in beverage packaging. Besides, the new inventions in the product are making the use of aluminum even better in the market. Some of the improvements include customization of shape and enhanced drinkability and pourability aspects.
Works Cited
“How Are Aluminum Cans Made?.” Earth911. 2019. www.earth911.com/recycling/metal/aluminum-can/how-are-aluminum-cans-made. Accessed 6 Dec. 2019.
Kiffaya Abood and Layla Muhsan.” Recycling of Aluminum Beverage Cans.” Journal of Engineering and Development, vol. 12, no 3, 2008.
Karen, Chew. “ Manufacturing the Aluminum Beverage Can: Raw Materials. Design Life Cycle. 2013. www.designlife-cycle.com/aluminum-soda-cans#_ftn6. Accessed 6 Dec. 2019.
Pinkyam, Myra. “Aluminum Cans-History, Development and Market” Azo materials. 2002. www.azom.com/article.aspx?ArticleID=1483. Accessed 6 Dec. 2019.
“The Aluminum Can Advantage” Key Sustainability Performance Indicators for the Aluminum Can. The Aluminum Association. 2019. www.aluminum.org/aluminum-can-advantage. Accessed 6 Dec. 2019.
“The Aluminum Page: How Aluminum is Produced.” Rockman’s Rocks, Minerals and Fossils. 2013. www.rocksandminerals.com/aluminum/process.htm>. Accessed 6 Dec. 2019.
“The Beverage Can’ Can makers. www.canmakers.metalpackagingeurope.org/sites/default/files/downloads/The-Beverage-Can-A-White-Paper.pdf. Accessed 6 Dec. 2019.
“Closing the loop: Design for Recovery Guideline: Aluminum Packaging.”Greenblue.2011. www.kidv.nl/6290/closing-the-loop-design-for-recovery-guidelines-aluminum-packaging-greenblu-sustainable-packaging-coalition.pdf?ch=DEF. Accessed 6 Dec. 2019.
Woodward, Angela. “Aluminum Beverage Can.” How products are made. 2019 www.madehow.com/Volume-2/Aluminum-Beverage-Can.html. Accessed 6 Dec. 2019.
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