Aluminium Cans Manufacturing Plant

Report Overview:

IMARC Group’s report, titled “Aluminium Cans Manufacturing Plant Project Report 2025: Industry Trends, Plant Setup, Machinery, Raw Materials, Investment Opportunities, Cost and Revenue,” provides a complete roadmap for setting up an aluminium can manufacturing plant. It covers a comprehensive market overview to micro-level information such as unit operations involved, raw material requirements, utility requirements, infrastructure requirements, machinery and technology requirements, manpower requirements, packaging requirements, transportation requirements, etc. The aluminium can project report provides detailed insights into project economics, including capital investments, project funding, operating expenses, income and expenditure projections, fixed costs vs. variable costs, direct and indirect costs, expected ROI and net present value (NPV), profit and loss account, financial analysis, etc.

What are Aluminium Cans?

Aluminium cans are lightweight, durable, and recyclable containers widely used for packaging beverages like energy drinks, soft drinks, and beer, as well as food products. Made primarily from aluminium sheets, these cans are valued for their ability to preserve freshness and protect contents from light, air, and moisture. They are highly sustainable, as aluminium is 100% recyclable without losing quality. The cans are also corrosion-resistant and easy to transport due to their lightweight nature. Their widespread use is driven by consumer demand for convenient, portable, and eco-friendly packaging solutions.

Aluminium Cans Manufacturing Plant: Key Highlights

• Process Used: Two-piece drawing and ironing (D&I) process
• End-use Industries: Beverages, food, pharmaceuticals, personal care, and household products
• Applications: Used in packaging soft drinks, energy drinks, beer, juices, canned food, aerosol products, and pharmaceutical sprays

An aluminium cans manufacturing plant is a facility that manufactures lightweight, durable cans through processes such as the two-piece drawing and ironing (D&I) process. The primary element of the plant includes coil handling systems, cupper presses, body makers, ironing, trimming, washers, decorators for printing, necking and flanging, and curing ovens. In order to manufacture high-quality aluminium cans, plants including the coil handling systems, cupper presses, body makers, ironing, trimming, washers, decorators for printing, necking and flanging, and curing ovens must have excellent quality control systems, automated material handling systems, and spill containment systems to ensure that product consistency is maintained, waste is kept to a minimum and recycling is maximized. Additionally, safety features in these plants are critical, due to the high speeds of the machinery employed and the metal-forming processes. An aluminium can plant may service beverage, food, personal care, pharmaceutical, and household goods sectors within the industries.

Aluminium Cans Industry Outlook 2025:

The aluminium cans market is driven by increasing demand for sustainable and recyclable packaging, as consumers and companies move toward eco-friendly solutions. Rising consumption of beverages, including soft drinks, energy drinks, and beer, is increasing demand for durable, lightweight cans. Additional demand is attributed to the cost-efficiency of aluminium cans since their lightweight nature reduces transportation costs. Furthermore, government regulations promoting recycling and commitments to sustainable practices from companies are pushing manufacturers to become more eco-conscious in their packaging. In addition, the advancement of technology in can design and printing, along with the growth of ready-to-drink (RTD) beverages and canned foods are increasing the expansion of the market. For example, Coca-Cola's Smart Water introduced creatively designed aluminum cans in April 2024, and it was announced that Smartwater Original and Smartwater Alkaline with antioxidants would be available for purchase in 12-ounce single-serve cans throughout the United States. This indicates a definite consumer preference for convenient and eco-friendly packaging.

Aluminium Cans Market Trends and Growth Drivers:

Surge in E-commerce industry

The rapid growth of e-commerce globally is driving the growth of the aluminium cans market. Online shopping is expanding globally and creating demand for safe, lightweight, and convenient packaging that has good durability and structural integrity for long shipping cycles. Importantly, the durable, portable and recyclable properties of aluminium cans make them desirable for beverage, personal care and household products sold on e-commerce. For instance, India is experiencing a boom in its e-commerce sector, which is expected to grow at a CAGR of 27% and reach US$ 163 billion by 2026 (IBEF). This growth is indicative of a global trend where e-commerce is accelerating demand for durable and eco-friendly packaging solutions like aluminium cans.

Expansion of beverage variety supporting aluminium cans

The global aluminium cans market is experiencing considerable growth since producers are switching to aluminium packaging instead of glass packaging due to its superior recyclability, light weight, and cost competitiveness. Aluminium is infinitely recyclable, and while there are countless advantages over glass, including reduced transportation costs, lower carbon footprints, and recycling benefits, the market appears to be driven by the rise in consumer and corporate focus on sustainability and operational excellence. For example, in June 2023, Marlish Waters Ltd, a UK based drinks producer, announced that its tonics and mixers would be available in a new 150 ml aluminium can format, switching from glass to provide a cheaper, greener, fully recyclable packaging. The trend to replace glass with aluminium is a far broader global phenomenon reflected across many beverage segments.

Latest Industry Developments:

• May 2024: To launch aluminum packaging for dairy products, Ball Corporation, a pioneer in environmentally friendly packaging, teamed up with CavinKare, a significant participant in the dairy sector. As a result of this partnership, CavinKare's well-liked milkshake line will now be available in Ball's two-piece aluminum cans, enhancing the brand's market share in aluminum packaging.
• February 2024: Every Can Counts, a recycling program, extended its activities to the US. Key industry participants, including packaging producers Ardagh Metal Packaging, CANPACK, Crown Holdings, and Envases, as well as aluminum suppliers Constellium, Kaiser Aluminum, Novelis, and Tri-Arrows Aluminum, collaborated on this launch with the goal of encouraging the recycling of beverage cans.
• January 2024: NOMOQ, a prominent European provider of digitally printed cans, unveiled its Blank Cans Service for beverage companies. With the help of this new service, marketers can now buy aluminum cans without decorations, giving them more personalization options outside of the company's typical printed designs.
• August 2023: Helvetia Packaging AG, a beverage can manufacturing plant in Saarlouis, Germany, was purchased by Crown Holdings Inc. With this transaction, Crown expanded its production capacity in Europe by almost one billion cans annually and entered the German market. The market for beverage cans in both the alcoholic and non-alcoholic segments is still being driven by the increased emphasis on sustainability and aluminum's capacity to be recycled.

Leading Aluminium Cans Manufacturers:

Leading manufacturers in the global aluminium cans market include several multinational packaging companies with large-scale production capacities and diverse product portfolios. Key players include:

• Crown Holdings, Inc.
• Ball Corporation​​
• CAN-PACK SA​
• Silgan Holdings Inc.​
• Ardagh Group S.A.

all of which operate large-scale facilities and serve end-use sectors such as beverages, food, pharmaceuticals, personal care, and household products.

Aluminium Cans Plant Setup Requirements

Detailed Process Flow:

The manufacturing process is a multi-step operation that involves several unit operations, material handling, and quality checks. Below are the main stages involved in the aluminium cans manufacturing process flow:

• Unit Operations Involved
• Mass Balance and Raw Material Requirements
• Quality Assurance Criteria
• Technical Tests

Key Considerations for Establishing a Aluminium Cans Manufacturing Plant:

Setting up a aluminium cans manufacturing plant requires evaluating several key factors, including technological requirements and quality assurance. Some of the critical considerations include:

• Site Selection: The location must offer easy access to key raw materials such as aluminium sheets or coils, typically made from aluminium alloys like AA3104 or AA3004, along with lubricants, coatings, and inks for printing. Proximity to target markets will help minimize distribution costs. The site must have robust infrastructure, including reliable transportation, utilities, and waste management systems. Compliance with local zoning laws and environmental regulations must also be ensured.​
• Plant Layout Optimization: The layout should be optimized to enhance workflow efficiency, safety, and minimize material handling. Separate areas for raw material storage, production, quality control, and finished goods storage must be designated. Space for future expansion should be incorporated to accommodate business growth.​
• Equipment Selection: High-quality, corrosion-resistant machinery tailored for aluminium cans production must be selected. Essential equipment includes cupper presses, body makers, trimmers, neckers, flangers, washers, coating and printing machines, and curing ovens. All machinery must comply with industry standards for safety, efficiency, and reliability.​
• Raw Material Sourcing: Reliable suppliers must be secured for raw materials like aluminium sheets or coils, typically made from aluminium alloys like AA3104 or AA3004, along with lubricants, coatings, and inks for printing to ensure consistent production quality. Minimizing transportation costs by selecting nearby suppliers is essential. Sustainability and supply chain risks must be assessed, and long-term contracts should be negotiated to stabilize pricing and ensure a steady supply.
• Safety and Environmental Compliance: Safety protocols must be implemented throughout the manufacturing process of aluminium cans. Advanced monitoring systems should be installed to detect leaks or deviations in the process. Effluent treatment systems are necessary to minimize environmental impact and ensure compliance with emission standards.​
• Quality Assurance Systems: A comprehensive quality control system should be established throughout production. Analytical instruments must be used to monitor product concentration, purity, and stability. Documentation for traceability and regulatory compliance must be maintained.

Project Economics:

​Establishing and operating a aluminium cans manufacturing plant involves various cost components, including:​

• Capital Investment: The total capital investment depends on plant capacity, technology, and location. This investment covers land acquisition, site preparation, and necessary infrastructure.
• Equipment Costs: Equipment costs, such as those for cupper presses, body makers, trimmers, neckers, flangers, washers, coating and printing machines, and curing ovens, represent a significant portion of capital expenditure. The scale of production and automation level will determine the total cost of machinery.​
• Raw Material Expenses: Raw materials, including aluminium sheets or coils, typically made from aluminium alloys like AA3104 or AA3004, along with lubricants, coatings, and inks for printing, are a major part of operating costs. Long-term contracts with reliable suppliers will help mitigate price volatility and ensure a consistent supply of materials.​
• Infrastructure and Utilities: Costs associated with land acquisition, construction, and utilities (electricity, water, steam) must be considered in the financial plan.
• Operational Costs: Ongoing expenses for labor, maintenance, quality control, and environmental compliance must be accounted for. Optimizing processes and providing staff training can help control these operational costs.​
• Financial Planning: A detailed financial analysis, including income projections, expenditures, and break-even points, must be conducted. This analysis aids in securing funding and formulating a clear financial strategy. 

Capital Expenditure (CapEx) and Operational Expenditure (OpEx) Analysis:

Capital Investment (CapEx): Machinery costs account for the largest portion of the total capital expenditure. The cost of land and site development, including charges for land registration, boundary development, and other related expenses, forms a substantial part of the overall investment. This allocation ensures a solid foundation for safe and efficient plant operations.

Operating Expenditure (OpEx): In the first year of operations, the operating cost for the aluminium cans manufacturing plant is projected to be significant, covering raw materials, utilities, depreciation, taxes, packing, transportation, and repairs and maintenance. By the fifth year, the total operational cost is expected to increase substantially due to factors such as inflation, market fluctuations, and potential rises in the cost of key materials. Additional factors, including supply chain disruptions, rising consumer demand, and shifts in the global economy, are expected to contribute to this increase.

Capital Expenditure Breakdown:

Operational Expenditure Breakdown:

Profitability Analysis:

Report Coverage:

Report Customization

While we have aimed to create an all-encompassing aluminium cans plant project report, we acknowledge that individual stakeholders may have unique demands. Thus, we offer customized report options that cater to your specific requirements. Our consultants are available to discuss your business requirements, and we can tailor the report's scope accordingly. Some of the common customizations that we are frequently requested to make by our clients include:

• The report can be customized based on the location (country/region) of your plant.
• The plant’s capacity can be customized based on your requirements.
• Plant machinery and costs can be customized based on your requirements.
• Any additions to the current scope can also be provided based on your requirements.

Why Buy IMARC Reports?

• The insights provided in our reports enable stakeholders to make informed business decisions by assessing the feasibility of a business venture.
• Our extensive network of consultants, raw material suppliers, machinery suppliers and subject matter experts spans over 100+ countries across North America, Europe, Asia Pacific, South America, Africa, and the Middle East.
• Our cost modeling team can assist you in understanding the most complex materials. With domain experts across numerous categories, we can assist you in determining how sensitive each component of the cost model is and how it can affect the final cost and prices.
• We keep a constant track of land costs, construction costs, utility costs, and labor costs across 100+ countries and update them regularly.
• Our client base consists of over 3000 organizations, including prominent corporations, governments, and institutions, who rely on us as their trusted business partners. Our clientele varies from small and start-up businesses to Fortune 500 companies.
• Our strong in-house team of engineers, statisticians, modeling experts, chartered accountants, architects, etc. has played a crucial role in constructing, expanding, and optimizing sustainable manufacturing plants worldwide.