Reducing the weight of aluminum cans can actually lead to huge savings in manufacturing and shipping costs. In a 2022 study by the Aluminum Association, it was discovered that a 1-gram reduction in aluminum can weight could save the beverage industry $1 million annually in manufacturing costs. This is largely attributed to the raw material cost savings since the lighter cans require less aluminum, and the metal is one of the largest production costs.
The concept of lightening aluminum can weight dates back a while. For example, Coca-Cola began lightening the weight of their cans as early as 2008, allowing the company to cut its production cost by 10%. The company achieved this by implementing more advanced manufacturing techniques, such as thinner aluminum without a reduction in structural can integrity. By 2020, Coca-Cola had saved approximately $40 million annually in production costs through these changes.
In addition to the real savings in manufacturing, a lighter aluminum can also saves transportation. Lighter aluminum cans allow more units to be shipped per shipment, thus less fuel consumption and transport cost. As cited by the International Aluminum Institute, an office study showed that shipping lighter products could save 5% to 10% on logistics, depending on scale of operations and frequency of shipments.
In addition, the environmental impact of reducing the weight of aluminum is considerable. There is less energy consumption in terms of production and transportation with light cans, therefore the overall carbon footprint reduces. An Environmental Protection Agency report issued in 2021 estimated that a reduction in the weight of aluminum cans by 2% would reduce the carbon emission of the beverage industry by 1.5 million tons annually, which means weight reduction leads not only to saving but also supporting sustainability.
In actual terms, companies that have adopted these strategies have earned huge returns. For instance, beer companies that introduced weight-reducing innovations in packaging experienced a mean reduction in packaging costs by 8%, while improving the efficiency of their supply chains. The use of recycled aluminum also plays a huge role, as it reduces the energy and raw material costs of production, leading to further savings.
The trend of light-weighting cans is gaining momentum in industries. The beverage industry, for example, is keen to maximize their packaging efficiency in order to stay ahead of the game. “New packaging can be a big help to the bottom line,” remarks Linda Grant, director of sustainable packaging at AB InBev. “By focusing on light cans, we can minimize our environmental impact and maximize our margins.”
Cutting companies’ production expenses by reducing aluminium can weight without compromising product quality is a proven step with monetary and environmental benefits.