Metal Packaging Sustainability Trends

A diverse range of robust coatings, lightweighting and renewable energy investments are improving sustainability for all types of metal packaging. Image courtesy of PPG.

What’s ahead for consumer-packaged goods brands and can makers.

By Melissa MacDonald, Ph.D., PPG Sustainability Partner, Packaging Coatings

As global expectations for sustainability continue to evolve, brands and can makers producing consumer packaged goods (CPG) face mounting pressure to adapt. Today, cutting carbon emissions, improving metal packaging recycling rates, and reducing waste are no longer optional — they’re critical to staying competitive. In addition to the environmental benefits, these initiatives also create opportunities for brands and canmakers to enhance operational efficiency and build stronger connections with consumers who value sustainability.

Let’s explore key sustainability trends reshaping the metal packaging landscape for CPG brands and canmakers, from lightweighting to renewable energy investments, and how the industry can lead the charge toward a more circular economy.

Drive Circularity and Lightweighting

Metal packaging has long been a champion of circularity, with recycled materials at its core. Aluminum is one of the highest value materials in a recycling bin. With an average of 71% recycled content, aluminum beverage cans are among the most recyclable packaging options available today, according to the Aluminum Association. Aluminum can also be re-used infinitely and does not degrade in quality. The Recycling Partnership highlights that used aluminum cans can be transformed and returned to shelves as new products in just 60 days — a powerful example of closed-loop recycling.

Lightweighting has become a key focus in sustainable packaging similar to other industries such as aerospace and automotive. By minimizing packaging weight, manufacturers can help reduce carbon emissions from transportation and raw material consumption, which is why many of the major canmakers around the world have made strides to reduce the thickness of their cans. For example, German aerosol can manufacturer Tubex reduced the weight of its cans by 20%. This reduction also has an effect on the overall weight of the pallets, which increases loading capacity. Overall, lightweighting demonstrates how small design changes can deliver lower emissions associated with transportation and logistics.

Expand Reuse and Refill Systems

The reusable and refillable packaging market is expected to grow 4.1% by 2032. With its durability and recyclability, metal remains ideal for packaging approaches that seek to reduce single-use waste. For instance, in an effort to reduce single-waste plastics, PATH Water aluminum bottles can be refilled and reused which has prevented 335 million bottles from entering our oceans and landfills, according to their website. Innovations like this show how metal can play a vital role in the circular economy, especially as more consumers demand refillable solutions.

Support Recycling Awareness

Despite the high recyclability of metals, industry reports show the U.S. recycling rate averages 43%, leaving room for improvement. What’s the barrier? The industry needs to work to boost low consumer awareness and invest in recycling infrastructure to achieve greater recycling rates. The packaging industry can help tackle this barrier through industry and community initiatives. For example, many industry partners are sponsoring the 2 Million Cans Recycling Contest, a U.S. initiative organized by Can Manufacturers Institute and Recycling is Like Magic! to encourage elementary students to recycle cans at their school. Supporting recycling initiatives helps keep packaging materials in the loop and helps reduce waste sent to landfills.

It also has an economic impact as well. According to Ball’s 50 States of Recycling report, increasing the aluminum can recycling rate to 90% would generate $6.6 billion for the U.S. economy and add more than 100,000 jobs.

Invest in Renewable Energy

Renewable energy investment marks another opportunity to evolve sustainability commitments. Manufacturers can significantly reduce carbon emissions by integrating solar, wind and other renewable energy sources into their operations. Global companies have recently made investment announcements. Recently, a paint and coatings company announced the completion of an on-site solar installation at its Caivano, Italy facility, which is anticipated to reduce greenhouse gas emissions by 390 metrics tons each year and annual operating costs by up to 15%.

Major canmakers have recently invested in Virtual Power Purchase Agreements (VPPA) to support renewable electricity and wind power projects. When all parts of the supply chain —suppliers, manufacturers and CPG brands — collaborate to use or support renewable energy sources, their combined efforts help reduce the carbon emissions associated with packaging production. This investment complements the environmental benefits across the packaging life cycle.

Removing MOCs in Coatings

In the metal packaging industry, coatings protect products and enhance shelf life, but companies are shifting to low volatile organic content (VOCs) and waterborne coatings to offer more sustainable alternatives. Lower VOC emissions and flammability are a key benefit to waterborne technologies.

In addition to VOC reduction, brands prioritize coatings free from materials of concern, such as bisphenol A (BPA). For example, brands and canmakers are adopting non-BPA internal coatings, which can offer high performance while aligning with sustainability goals. As a result, they meet the evolving global regulatory requirements and build consumer trust, reinforcing their commitment to sustainability.

Collaborate to Reduce Footprints

The Science Based Targets Initiative (SBTi), a collaboration that helps companies and financial institutions set science-based targets to reduce greenhouse gas (GHG) emissions, is gaining traction, with more than 9,000 companies committing to reduce their emissions. The initiative develops standards, tools and guidance which allow companies to set scope 1, 2 and 3 greenhouse gas emissions reduction targets, in line with the goals of the Paris Agreement. As a part of scope 3 downstream emissions reduction initiatives, coatings manufacturers are increasingly collaborating with customers, such as canmakers, to help lower emissions through product innovation and process improvement solutions.

Through lifecycle assessments (LCAs) and carbon footprint analyses, coatings partners can provide data-driven insights to support decarbonization strategies. Joint efforts like this help can manufacturers pinpoint improvement areas such as:

1. Raw materials: Sourcing low-carbon, recyclable materials that maintain durability
2. Manufacturing: Investing in renewable energy and efficient production methods
3. Transportation: Optimizing local supply chains to reduce emissions
4. Application: Leveraging coatings with lower film builds, higher solids and efficient application
5. Disposal/Recycling: Designing solutions for recyclability or for other end-uses (i.e., coating can be used as fuel in can recycling) to support circular economies

No company can tackle sustainability alone. It’s important to note that when canmakers and brands make changes to the metals and the ingredients, it impacts the coatings. Coating technology is complex, and with these changes, we must ensure that coatings are robust, versatile and compliant for all metal packaging solutions. These industry collaborations foster innovation and enable CPG brands and canmakers to align sustainability targets across the value chain.

Lead the Way to a Sustainable Future

Companies must consider circularity, lightweighting, renewable energy, specialized protective coatings and consumer recycling awareness to address environmental challenges head-on and deliver long-term benefits, from improved operational efficiency to enhanced brand reputation.

As sustainability increasingly becomes a consumer expectation, manufacturers, CPG brands and canmakers have an opportunity to lead the transformation. By working together, the industry can shape a future where packaging is both high-performing and sustainable.

About the Author

Melissa MacDonald, Ph.D., is a PPG Sustainability Partner. With an extensive background as a research chemist and project leader, Melissa has made significant contributions to the coatings industry. In Packaging Coatings, she works closely with the PPG team and customers to drive greater sustainability solutions. For more information about PPG’s Packaging Coatings business, visit packagingcoatings.com.