Firms create bespoke aluminum cans with the assistance of advanced printing technology, material science, and brand strategy to create unique, premium packaging that is attractive to consumers. The global aluminum packaging market was valued at $45.5 billion in 2022 and is forecasted to post a CAGR of 4.5%, increasing due to demand for bespoke branding, sustainability, and light-weight packaging solutions.
The process starts with the selection of materials. Most aluminum cans are made of 3004 and 3104 aluminum alloys that contain approximately 1% manganese and 1% magnesium for added strength, corrosion resistance, and recyclability. The average 12-ounce aluminum can weighs about 14 grams and can withstand up to 90 psi of internal pressure, making it ideal for carbonated beverages, energy drinks, and specialty craft beers.
Businesses utilize digital printing, offset lithography, or flexographic printing to create high-res images on cans. Offset lithography is most common method practiced, with capacity for printing up to 2,000 cans a minute in detailed, multicolored art. UV-cured inks and aqueous coatings assist in keeping designs intense and resistant to moisture, sunlight, and changing temperatures.
Customization extends to the print component as businesses opt for matte, gloss, or textural coatings to include consumer appeal. Coca-Cola introduced color-shifting aluminum cans in 2023 using temperature-acting thermochromic ink to provide a changing consumer experience. Brands include emboss or raised texture, adding distinction to brands in a crowded marketplace.
The cost of personal aluminum cans is based on how many are purchased, the technique of printing, and the degree of personalization. Digital printing allows for minimum orders of low volumes of around 500 cans, whereas large-scale printing in bulk with the use of offset techniques requires at least 50,000 pieces per run. The price per can can go from $0.10 to $0.50, subject to design complexity and material specifications.
Sustainability remains an important consideration in the design of aluminum cans. Over 75% of all aluminum ever produced is still in use today, and it is one of the most recyclable packaging materials available, states The Aluminum Association. Large companies such as PepsiCo and Anheuser-Busch have committed to using 50% recycled content in their aluminum cans by 2030, reducing carbon emissions and energy consumption.
Marketing expert Seth Godin once said, “A brand is the set of expectations, memories, stories, and relationships that, taken together, account for a consumer’s decision to choose one product over another.” Custom aluminum cans increase brand awareness, customer engagement, and product visibility, which is why beverage corporations, craft breweries, and energy drink producers all over the world utilize them. The ability to make customized aluminum cans provides businesses with a competitive edge, as the products become more unique in an increasingly saturated marketplace.