Quick overview: Coatings used in cans are changing in response to restrictions on substances such as BPA and PFAS, new beverage formulations and environmental criteria. BPA-NI systems, water-based acrylics and polyesters are among the alternatives already in use or under evaluation to maintain chemical resistance, adhesion, flexibility and corrosion protection. The right choice depends on the packaged product, substrate and processing conditions.
Contents
- What is changing in can protection
- BPA and PFAS are changing metal packaging coatings
- Which coatings are being adopted by the industry?
- New beverages bring new challenges for aluminum protection
- Sustainability is also shaping coating choices
- How to evaluate a new coating before taking it to the production line
- Frequently asked questions
What is changing in can protection
Metal packaging coatings are going through one of the most significant formulation shifts in recent decades. Restrictions on certain substances, new beverage categories moving into cans and environmental targets are adding new requirements to a layer that must protect the metal, preserve the product and withstand high-speed manufacturing.
This combination is also changing what needs to be considered when selecting a coating. Abeaço highlights factors such as coating thickness, adhesion and the characteristics of the packaged product, along with the different stages involved in manufacturing the container. BPA-NI systems, water-based acrylic formulations and polyester-based alternatives are among the options being developed to meet these requirements.
The challenge is to change the formulation without losing the properties already expected from can coatings. Chemical resistance, flexibility and corrosion protection remain essential, now alongside stricter regulatory and environmental criteria. Here is what is driving these changes and which alternatives are already being used.
BPA and PFAS are changing metal packaging coatings
The European Union banned the use of bisphenol A (BPA) in food-contact materials under Regulation (EU) 2024/3190. The measure includes coatings applied to metal cans and establishes transition periods depending on the application. The regulation covers hundreds of BPA-based epoxy resin formulations used in coatings and varnishes, making replacement a complex task across a wide range of products and applications.
Another change came into effect in August 2026. The European Union’s Packaging and Packaging Waste Regulation (PPWR) established limits for per- and polyfluoroalkyl substances (PFAS) in food-contact packaging. Products placed on the European market after August 12, 2026, must comply with the limits set by the regulation.
These rules also affect companies outside Europe that serve European customers or maintain commercial operations in the region. Coating specifications need to take into account where the packaging will be sold and which regulations apply in each market, which may require different specifications for different destinations.
This is also relevant to the Brazilian industry. Between January and July 2026, Brazilian packaging exports reached US$363.9 million, up 11.8% compared with the same period in 2025, according to a study by ABRE in partnership with FGV. Metal packaging accounted for 34.4% of that total, the second-largest share among exported packaging materials. With metal packaging representing a significant portion of exports, regulatory changes in destination markets can directly affect product specifications and coating choices.
Replacement, however, requires planning. New formulations need to undergo safety, performance, shelf-life and packaging compatibility testing before commercial-scale adoption. Keeping ahead of regulatory changes gives companies more time to evaluate alternatives and prepare their production lines before new requirements affect the markets they serve.
Which coatings are being adopted by the industry?
BPA-NI coatings and water-based acrylic systems are among the alternatives already being used commercially. Polyesters are also being studied and used across different packaging applications. They all share a common requirement: maintaining the adhesion, flexibility and chemical resistance delivered by conventional systems.
A scientific review published in 2026 in Progress in Organic Coatings examines this transition and identifies BPA-NI coatings among the alternatives developed to replace BPA-based systems. In Brazil, products in this category are already available for beverage cans, including water-based internal coatings designed for high-speed lines. Some of these technologies have been commercially used in other countries for more than a decade, showing that the transition has already reached industrial scale.
Water-based acrylic polymer systems are another option currently available. They are already used as internal coatings for aluminum and steel beverage cans, with reported applications across billions of cans worldwide. This experience at scale has established acrylic systems as one of the alternatives available for internal can coatings.
Polyesters are used in a range of applications and can be formulated to meet different packaging requirements. Flexibility, chemical resistance and performance during forming are among the properties considered, particularly when the material needs to withstand mechanical operations before filling.
The choice between these technologies depends on the application. Substrate, coating thickness, packaged product, processing temperature and storage conditions all affect performance. The most suitable option is the one that can meet the specific conditions of both the packaging and its contents throughout production and shelf life.
| Technology or feature | Why it is being discussed | Technical requirements |
| BPA-NI / BPX-NI | Replacement of bisphenols in response to new regulatory requirements | Chemical resistance, adhesion, flexibility and corrosion protection |
| Water-based acrylics | An alternative already used for internal beverage can applications | Coverage, sensory performance and compatibility with high-speed lines |
| Polyesters | Potential for BPA-free systems across different applications | Flexibility, chemical resistance and performance during forming |
| PFAS-NI formulations | PFAS limits for food-contact packaging in the European Union | Maintaining performance without the intentional use of these substances |
| Water-based external coatings | New composition and industrial performance requirements | Abrasion resistance, printability, finishing and processing performance |
New formulations are also reaching easy-open aluminum can ends. In 2025, coatings manufacturer PPG expanded its portfolio for this application with internal and external BPA-NI and PFAS-NI options designed to withstand hot-fill, retort and pasteurization processes, as well as the mechanical requirements involved in can-end manufacturing.
New beverages bring new challenges for aluminum protection
Energy drinks, wines, coffees, protein shakes and plant-based beverages are appearing more frequently in cans. This is good news for the segment, bringing new applications for metal packaging, but each beverage has its own characteristics that need to be considered when selecting the internal coating.
Canned wine, for example, requires attention to sulfur dioxide levels. Coffees, protein shakes and some plant-based beverages may require higher processing temperatures to achieve stability. Acidity, alcohol and salt concentrations also vary considerably from one product to another and affect the level of protection required.
This means that a coating used for one beverage category will not necessarily perform the same way with another. Depending on the product, the formulation or coating thickness may need to be adjusted to maintain chemical resistance and prevent corrosion. The review published in Progress in Organic Coatings addresses this issue by examining coating performance across beverages with different characteristics.
The market already offers formulations designed for these newer applications, but moving them onto the production line requires compatibility and performance testing. Adhesion, chemical resistance, corrosion and potential sensory changes are among the factors evaluated before commercial-scale production.
As more beverage categories move into cans, these evaluations are likely to become increasingly application-specific. Producers and fillers need to balance the characteristics of each product with applicable requirements without creating new issues on the line or compromising packaging shelf life.
Sustainability is also shaping coating choices
When it comes to coatings, environmental performance involves several parts of production. Raw materials are one consideration, but so are coating weight, solvent use, volatile organic compound (VOC) emissions and the energy consumed during application.
Some formulations already provide measurable figures for comparison. For one BPA-NI internal coating based on acrylic resin, for example, the manufacturer reports a 22% lower carbon footprint when applied to a 330 ml can compared with the reference epoxy alternative.
This shift is also visible at industrial scale. Can manufacturer Ball reports that, in 2025, 72% of the cans it produced used BPA-NI internal coatings. For external PFAS-NI coatings, the figure reached 63% of its global production. The example shows that these formulations are already part of day-to-day manufacturing, rather than being limited to trials or development projects.
Water-based formulations and high-solids systems are also among the alternatives used to reduce solvent consumption and VOC emissions. But composition alone does not tell the whole story. Energy consumption, coating weight and production scrap also need to be considered.
Then there is durability. Reducing material use or changing a formulation needs to work without shortening the packaging’s expected service life. If a coating fails earlier than expected, corrosion, product loss and premature disposal may follow — exactly the opposite of the intended result.
This becomes even more relevant when considering the environmental progress already made by metal packaging itself. A life cycle assessment from Metal Packaging Europe, based on 2023 production data, reported an average 31% reduction in greenhouse gas emissions from the manufacture of aluminum beverage and food cans compared with the previous assessment. The figure covers the package as a whole, but it also reinforces the importance of coatings, inks and other materials used throughout production.
When we talk about circularity in metal packaging, then, the discussion starts well before recycling. Coating selection is part of that picture, both in terms of the materials and resources used during application and the coating’s ability to keep the package protected throughout its expected life.
How to evaluate a new coating before taking it to the production line
With so many formulations and new requirements on the radar, choosing a coating calls for an assessment that reflects the reality of each operation. An option that performs well with one beverage or production line may behave differently when the contents, package or processing conditions change.
Testing remains an important step before any commercial-scale change. pH, alcohol and salt content, temperature, storage time and expected shelf life are among the factors that can influence the choice. On the production line, forming, stamping, pasteurization, sterilization and retort conditions bring additional requirements.
Adhesion, chemical resistance, corrosion and product compatibility also need to be evaluated alongside the regulatory requirements of each market. As discussed above, comparisons now also include energy consumption, the amount of material applied, production scrap and other sustainability-related factors.
There is no single formulation that will perform the same way in every situation. The key is understanding what works for each application and, importantly, following what other companies are already putting into practice to make these changes without compromising production.
This will be one of the topics discussed at OneCan Summit & Expo 2027. The event brings together companies, partner organizations and professionals already dealing with these changes in production, creating space to share experiences, technologies and alternatives being adopted across the market. It is an opportunity to compare options, understand what may work for your company’s operation and meet potential partners for upcoming projects.
From April 6 to 8, 2027, at Distrito Anhembi in São Paulo, OneCan Summit & Expo will bring together different parts of the metal packaging value chain for these conversations.
Want to take a closer look at new technologies and meet partners for your company’s next projects? Join us at OneCan Summit & Expo 2027.
