For each 1g decrease in aluminium can weight, raw material costs can decrease by 0.8-1.2%, as stated by the International aluminium Association. Taking the Coca-Cola 330ml standard can as a case example, by reducing the wall thickness of the can from 0.28mm to 0.24mm and modifying the formula of the alloy, the weight of the individual can is reduced from 13.2 grams to 11.5 grams, the production of 20 billion cans per year is calculated, and the yearly consumption of aluminum is 340,000 tons, and the direct material cost is saved by 510 million US dollars (at the cost of 1,500 US dollars/ton of aluminum). This technology ensures the compressive strength of the tank ≥310N, is consistent with the specifications of the ISO 90 standard, and damage rate is regulated below 0.05%, i.e., 40% lower than that of the traditional tank type.
In the manufacturing process, the light weight of the aluminium can reduce the stamping cycle by 12%. With the introduction of light tanks, AB InBev upgraded production speed in its German factory from 2,400 to 2,700 cans a minute, reducing unit energy consumption by 18% and reducing €2.8 million in electricity costs annually. At the same time, the life of mold is extended from 800,000 times to 1.2 million times by decreasing the impact pressure, and maintenance cost is decreased by 35%. For every 10% weight reduction in aluminum cans, the overall efficiency of the production line could be increased by 6.5%, says the American Packaging Association.
Logistically, lightening the weight of aluminium cans by 15% can raise the standard pallet load by 23%. Lightening the weight of its 500ml cans from 20g to 17g and increasing pallet load from 1,920 to 2,360 cans, Heineken reduced 19% of vehicles per lot, saving $12 million annually in fuel and lowering CO2 by 28,000 tonnes. The report from the European Beverage Association shows that the cost of transportation for lightweight cans made of aluminum is 14.7% cheaper than regular cans, and damage to cargo is reduced from 0.3% to 0.08%.
Environmentally, for every 1 gram weight reduction of the aluminium can, life-cycle carbon footprint reduces by 0.023kg CO₂e. Carlsberg Group’s 2025 sustainability report reports that its light aluminium cans (13% reduction on the baseline) have reduced carbon emissions per tank from 148g to 129g, and increased use of recycled aluminium to 75%, reducing carbon emissions by 430,000 tons per year. It has been certified by the European Union’s Packaging and Packaging Waste Directive that stops companies from paying the environmental tax of 120 euros per ton of unused aluminium.
Technically, getting aluminium can weight below 11 grams means going against material boundaries. Daiwa Canning, Japan, has designed the “Nano Coat” nano coating technology which guarantees the axial load capacity of ≥280N at tank wall thickness 0.21mm, improves the arc Angle radius of the bottom of the tank to 0.8mm (from 1.2mm) using 3D stress simulation, and increases the pressure bearing capacity of the bottom by 27%. The technology invested $42 million in research and development, but achieved a 9% reduction in cost per tank and a reduction in the return on investment period to 3.2 years.
Market acceptance figures show that lightweight aluminium can improve shelf display efficiency by 18%. 83% of respondents claim they prefer to carry 12% lighter tanks and are 21% more likely to buy them, IPSOS Consumer reported. Pepsi launched 9.8 grams ultra-light cans in the Asia-Pacific market, through laser microsculpture technology to expand the tank printing area by 15%, with center of gravity optimization design, to decrease the failure rate of vending machine shipments from 1.2% to 0.3%.