Efficiency in can manufacturing depends on making better use of materials, reducing losses, improving equipment availability and using water and energy more efficiently. In an industry that produces billions of units, an improvement made at a single stage can deliver meaningful results across the entire operation. These are some of the topics that will be discussed at OneCan Metal Can Summit & Expo, where new solutions gain visibility and connect with the people shaping the industry’s next decisions.
Contents
- Efficiency in can manufacturing starts on the production floor
- Less material can deliver significant gains
- Better production also means fewer stoppages and losses
- Sustainability starts in the factory, before recycling
- A targeted solution can solve a major challenge
- Bringing a solution to the industry is also part of the process
- Frequently asked questions
1. Efficiency in can manufacturing starts on the production floor
When billions of packages roll off production lines every year, efficiency comes down to the smallest details. In Brazil alone, 34.1 billion aluminum beverage cans were sold in 2025, according to Abralatas, the second-highest volume ever recorded. At this scale, saving raw materials, using less energy, reducing production losses or keeping equipment running more consistently can translate into significant financial returns.
Opportunities to improve the line can be found throughout the process. Can body forming, washing, drying, printing, coating application and curing, inspection and material handling all rely on resources and equipment working together. Efficiency can improve through major innovations as well as refinements to processes that are already part of everyday manufacturing.
This creates very practical challenges for materials, equipment, components and technologies to address.
2. Less material can deliver significant gains
The history of the aluminum can itself shows how engineering and materials research can transform packaging over time. According to the Aluminum Association, the average weight of an aluminum can has fallen by 38% since the 1970s.
Reducing the amount of aluminum, however, requires a high degree of precision. The can still needs to remain strong enough to withstand filling, sealing, transportation, storage and stacking before it reaches the consumer. The challenge is to remove excess metal while preserving structural integrity.
This evolution involves research into alloys, design changes, tool development, thickness control and improvements in forming processes. When production runs into the billions, even a small material saving on each can can translate into a substantial result across the operation.
The same principle applies to other stages of manufacturing. Better use of inks and coatings, longer tool life and lower material losses during forming can all reduce the resources required to bring each package to market.
3. Better production also means fewer stoppages and losses
Speed matters, but it does not tell the whole story on a production line. A high-speed machine loses much of its advantage if it stops frequently, requires constant adjustments or continues producing defective cans before anyone detects the problem.
Sensors, monitoring systems, automation and predictive maintenance make it possible to track equipment performance in real time. Monitoring vibration, temperature and wear can provide early warning signs long before an issue develops into a failure that stops the line.
One example can already be found in Brazil’s aluminum can industry. A plant experiencing unexpected equipment stoppages developed a predictive analytics system using data from sensors already installed on its machines. This allowed the operation to identify potential failures earlier and plan maintenance more effectively, using information generated by the production line itself to reduce unplanned downtime.
Inspection follows a similar logic. Identifying a deviation before it is repeated across thousands of units makes it possible to address the source of the problem sooner, reducing waste and rework. In-line vision and quality control systems can also monitor characteristics that need to remain within defined parameters even at high production speeds.
Ultimately, productivity means maintaining a stable production rhythm, reducing interruptions, detecting problems quickly and making better use of the resources entering the line, while also producing more units in less time. The value of a new technology becomes clear when it increases capacity, reduces waste or makes production more reliable.
4. Sustainability starts in the factory, before recycling
Recycling receives much of the attention when sustainability and aluminum cans are discussed, and for good reason. In 2024, Brazil recycled 97.3% of the aluminum beverage cans sold in the country, according to data from the Brazilian Aluminum Association (ABAL) and Abralatas compiled by Recicla Latas. That represents 33.9 billion cans, equivalent to 417,700 metric tons of material.
Brazil has maintained a recycling rate above 96% for 16 years, but the environmental performance of a can also depends on what happens before it reaches the consumer.
Every can discarded during production has already required aluminum, electricity, water, chemicals and machine time. Making better use of each production batch also means making better use of all these resources.
The same principle applies elsewhere in the operation. Washing systems can use water more efficiently, equipment can consume less energy, thermal processes can be optimized and materials generated during manufacturing can be returned to the production cycle.
In practice, sustainability and cost efficiency are closely connected. Water, energy and aluminum all carry a financial cost as well as an environmental impact. Technologies that use these resources more efficiently can improve both sides of the equation.
5. A targeted solution can solve a major challenge
An innovation applied to one specific stage can have an impact that extends across the production chain. Metal packaging manufacturing brings together many different areas of expertise, and the performance of individual components and materials can influence the final result.
The list of technologies and resources involved is extensive, including raw materials, machinery, tooling, inks, coatings, chemicals, washing systems, inspection cameras, sensors, software, automation and energy systems. Each stage offers opportunities to improve day-to-day production. The table below shows where some of these solutions can be applied.
Where new solutions can improve can manufacturing
| Area | What can be improved |
| Raw materials | Weight, strength and material utilization |
| Forming and finishing | Precision, speed and production losses |
| Printing and coatings | Consumption, quality, curing and performance |
| Inspection and control | Early defect detection and production yield |
| Machinery and maintenance | Equipment availability and service life |
| Water and energy | Lower consumption across the plant |
| Material recovery | Reuse and return to the production process |
The possibilities vary considerably and address different production needs. The focus may be resource consumption, process stability, quality, maintenance or material utilization. This variety shows why different areas of expertise need to work together to keep manufacturing processes evolving.
6. Bringing a solution to the industry is also part of the process
Developing a technology capable of addressing one of these challenges is only part of the process. Bringing it into contact with professionals who understand production needs, evaluate applications and take part in purchasing and investment decisions gives that solution a chance to be seen and discussed by the market.
With this purpose, OneCan Metal Can Summit & Expo will bring together different parts of the metal packaging value chain from April 6 to 8, 2027, at Distrito Anhembi in São Paulo. Technologies, materials, equipment and services will share the same environment where technical challenges, efficiency and new possibilities for manufacturing will be discussed.
If your solution addresses any of these areas, taking part in the event is an opportunity to demonstrate where it can deliver results and connect with professionals who understand the industry’s needs.
ONECAN METAL CAN SUMMIT & EXPO
OneCan is Latin America’s first event dedicated entirely to the metal packaging market. The trade show brings together manufacturers, brands that use metal packaging and the professionals behind the production of cans, aerosols and other metal packaging formats.
7. Frequently asked questions
What does efficiency mean in can manufacturing?
It means using materials, machinery, energy, water and production time efficiently while minimizing waste and maintaining packaging quality. This can involve anything from changes in raw materials to automation, inspection, maintenance and process control.
What solutions can increase productivity in can manufacturing?
Automation, sensors, inspection systems, equipment monitoring, predictive maintenance, control software, new machinery and tooling are among the possibilities. Their impact depends on the production stage and the problem the technology is designed to address, such as downtime, material losses, process instability or frequent adjustments.
How can manufacturers reduce can production costs without compromising quality?
One approach is to focus on production losses and resource use by improving raw material utilization, reducing waste, lowering water and energy consumption and increasing equipment availability. The goal is to optimize resources while consistently delivering the required performance.
How can a company present its solution to the metal packaging industry?
Industry events provide a direct way to connect with the professionals involved in purchasing and investment decisions. OneCan Metal Can Summit & Expo will take place from April 6 to 8, 2027, at Distrito Anhembi in São Paulo, bringing together different segments of the metal packaging industry in an environment focused on business, technology and knowledge.
