6. CASE STUDY &#; HOW VALPURE® V70 CAN ENABLE THE TRANSITION TO SUSTAINABLE PACKAGING
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For aluminum cans to function as a sustainable solution, they require can coatings to protect the quality and integrity of the can and the products they contain.
valPure® V70 has the potential to enable significant change within the food and beverage, household, and personal care industries, which are beginning to favor more sustainable forms of packaging, such as aluminum cans, over other packing types, such as plastic and glass.
According to recent research, about 85 percent of consumers make purchasing decisions with sustainability in mind, and they especially care about packaging, with more than half of consumers saying that packaging must be ecofriendly.14
One of the more recent success stories in the switch to aluminum is the canned water industry, with global companies starting to package some of their water brands within aluminum cans. Supermarkets such as Tesco in Europe have offered canned water since . Some of the U.K.'s biggest food and drink wholesalers, such as Bidfood and Brakes, and have also chosen canned water in response to retailer and customer demands to reduce their plastic packaging.15 According to Metal Packaging Europe, the flavored and mineral waters market is one of the fastest growing in the world; currently valued at over &#;50 billion globally.16
Canned water has been linked to sustainable initiatives and brands with the U.K. brand, Dash, choosing cans for its waters flavored with misshapen fruit that would otherwise be thrown away by supermarkets. CannedWater4kids (CW4K), a nonprofit based in the U.S., which ensures all children across the globe have access to safe drinking water, funds its initiatives through the sale of its drinking water in aluminum bottles and cans.17
valPure® V70 is in full commercial use for some of the most challenging beverage types, including canned water, seltzers, wines, alcoholic beverages and sparkling waters. While canned water may not seem revolutionary, it can be a very technically challenging beverage to pack. This is due to the fact the flavor of canned water is neutral, as it lacks the high levels of sugar and flavorings found in other beverages. This means that the flavor profile of water could be easily impacted by certain can coating formulas. It is very important that the coatings used for canned water limit migration of materials from the coating which may affect the flavor profile of the water. Historically, BPA-based epoxy coatings have been the preferred coating to hold canned water due to the robust sensory performance of epoxy coatings.
Sherwin-Williams has worked closely with its customers to test a range of different coating formulas to successfully pack water in metal packaging. valPure® V70, as an epoxy technology, has performed well when used as a coating for canned water, making it the perfect partner to enable the growth of this exciting packaging sector.
Within the diverse range of brands and sub-sectors of the beverage industry, there is another key player that faces many challenges in transitioning to sustainable packaging &#; the wine industry.
Traditionally, the wine industry has favored the glass bottle. According to a recent study, bottling represents the largest percentage of greenhouse gas emissions relating to the production of wine.18 As the wine industry attempts to reduce its carbon footprint, half of its greenhouse gas emissions are attributed to the manufacture and transportation of glass bottles, which are created in energy-intensive furnaces.19
Glass is still the most practical packaging for inert wines that are meant to age over time in a cellar. However, for the 95 percent of all wine consumed within months of purchase, bottles are increasingly impractical with many wine producers reporting shortages of glass bottles.20 Some people in the industry, however, remain skeptical about the can, with some wine experts claiming that drinking wine from a can could diminish the quality and aroma of the wine.
Despite these concerns, the wine industry is increasingly considering metal packaging as a viable alternative, with cans valued for their sustainability benefits. The value of the global canned wine market is estimated to surpass &#;525 million ($570 million) by , at an average annual 13 percent growth.20
While glass is technically highly recyclable, in the U.S., only 31 percent of glass is recycled. However, aluminum is widely recycled with almost 75 percent of the aluminum that has ever been produced is still in use today.21
The manufacturing of such cans for the industry is also significantly more efficient, with the production of three 25cl aluminum cans, instead of a traditional 75cl wine bottle, reducing carbon emissions by 79%.22 Additionally, according to a survey by the Swedish government&#;s alcohol retail chain Systembolaget, reported in the Financial Times, a can is &#;28 times more efficient to recycle than bottles.&#; Cans of wine are smaller, lighter, more durable, and easier to store and recycle.22
However, for the wine industry to successfully transition to metal packaging, it needs innovative can coating technologies that protect its product, support shelf life, and do not impact the taste or quality of the wine. Maintaining the quality of wine in cans is challenging since many wines are very acidic and can degrade internal can coatings. This can lead to corrosion of the can, which can adversely affect the flavor of the wine. Coatings also need to be suitably flexible to avoid cracking during the sealing of the can. Cracks in the coating can lead to exposed aluminum, which can react with the sulfite preservatives in the wine to form hydrogen sulfide, which has a very unpleasant odor. Therefore, for a coating to be suitable to protect canned wine, it must be able to provide a strong barrier between the wine and the aluminum can and be flexible enough to remain intact during the sealing process. valPure® V70 is proven to have excellent barrier resistance and flexibility. This combination of properties makes valPure® V70 very effective for canned wine.
Indeed, for metal packaging to work successfully as a sustainable solution for the food and beverage industry, innovative can coatings are essential for preserving the integrity of these cans and the products they hold. The development of valPure® V70 supports this transition towards the increased use of metal packaging for the wine and water beverage sectors, offering an epoxy technology without the use of BPA.
The following article originally appeared in a print edition of 'Aluminium Today.' You can also clic&#;k here&#; to read it.
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Increased recycled aluminium demand has led to new aluminium-rolling capacity in the U.S. to supply the growing metal packaging industry. For instance, Novelis Inc. recently broke ground and began construction on its $2.5 billion recycling and rolling plant in Bay Minette, Alabama. Steel Dynamics Inc announced plans to build a recycled aluminium flat-rolled mill in Columbus, Mississippi.
The strong global aluminium packaging recycling rates drive the increased recycling capacity. According to Ball Corporation, the global recycling rate for aluminium beverage cans stands at 70%. Increasingly, leading industry bodies are establishing greater recycling goals. In fact, European Aluminium and Metal Packaging Europe launched a joint roadmap towards achieving 100% aluminium beverage can recycling by . Comparatively, plastic packaging&#;s recycling rate stands at 8.7%, a statistic published by the Environmental Protection Agency and last updated for . Compared to aluminium, plastic bottles, jars and other similar hard-to-collect, sort and recycle articles have a much lower recycling rate. Overall, aluminium&#;s homogenous material enables better recycling than plastics&#; multi-layered and varied packaging.
Global aluminium packaging recycling also aligns with consumer demand. A recent global consumer survey reveals a market opportunity for household and personal care brands to diversify their packaging mix with aluminium to meet today&#;s consumers&#; sustainability preferences and enable a circular economy. In response to greater consumer awareness of the environmental footprint of packaging, continued investor interest and innovations in metal packaging, major consumer packaged goods (CPG) brands are shifting to metal packaging. Coatings play a significant role in this transition.
The Aluminum Association estimates that almost 75% of all aluminium produced in the U.S. is still in use today and that recycled aluminium saves 95% of the energy needed to make new aluminium. In addition, Metal Packaging Europe reports that no other beverage packaging can reach such high recycling rates while using so little primary material, resulting in product circularity and carbon emissions reductions.
Additionally, more brands are shifting their primary packaging to post-consumer recycled (PCR) content. While PCR offers environmental and economic advantages that support a circular economy, coatings innovation remains at the forefront of enabling even greater incorporation of recycled content into aluminium packaging. PCR&#;s unique surface characteristics and material properties require a comprehensive package of progressive coating solutions for continued product protection.
In addition to PCR, the industry focuses on optimising packaging weight, which can lower waste, decrease costs and enhance product function. Aluminium&#;s lightweight, stackable, and strong characteristics allow brands to package and transport more products using less material. And many consumers prefer lightweight designs over heavier glass and plastic bottles.
Today&#;s global beverage market expands, adapts and evolves at an accelerated rate. A recent study by Market Research Future estimates that the U.S. beverage can market alone will reach $32.93 billion by . Consumer demand for new drink concepts is one market growth driver. These include ready-to-drink products, water, non-alcoholic beers, mocktails, coffees, energy drinks and nutrient- and herb-infused beverages. These drink products look to innovative packaging solutions that offer a distinctive design and sustainable packaging, such as recycled aluminium, to stand out in a crowded shelf space. Penrhos Spirits announced they would use new, fully recyclable aluminium bottles with their limited edition &#;Wonky Raspberry&#; gin. The company expects its packaging to be made from 100% recycled aluminium, cutting energy requirements, packaging, transport and carbon footprint. Penrhos will launch the new bottle later in .
Increasingly, cosmetics, personal care and household care brands are also realising the benefits of using aluminium packaging. In addition to recyclability and being lightweight, aluminium allows for a more modern design than plastic. The mono-material package allows a wide variety of logos, designs and functions, including eliminating adhesives and additional labels required with plastic packaging. Aluminium also offers a unique opportunity for brands to feature their personality. For instance, more brands turn to specialty finishes, such as matte and satin, as well as tactile and elaborate labels to bring their vision to life. By using diverse can sizes with a visual and textural surface, brands provide appealing visual and touch elements that create a memorable consumer experience.
One of the most interesting trends in cosmetic, personal, and household care packaging centres on refillable aluminium packaging driven by consumer demand for more environmentally responsible products. Unilever debuted a new line, Love Beauty and Planet, featuring shampoos and conditioners in reusable aluminium bottles to meet the needs of an evolving consumer base. Coatings innovation will continue to play a critical role in refillable aluminium packaging to protect substances from spoilage or quality degradation throughout the product&#;s entire shelf life.
Coatings advancements support industry trends toward a wider array of shapes and customised printing options to ensure products stand out despite increasingly crowded shelf space. They can add aesthetic and functional elements to packaging to help create visual and tactile experiences for the consumer and differentiate the brand.
In addition to the packaging design, coatings solutions enable a greater post-consumer recycled mix in packaging, support lightweight metal packaging, prevent abrasion or damage prevention of products during transit and protect the integrity of the product for consumer safety. Interior coatings advancements preserve the product, minimise coating migration, and comply with applicable global regulations. These innovative coatings must allow easy and reliable application in varying conditions, temperatures, and humidity in different plants worldwide.
An integrated coatings partner helps ensure improved production for can makers as more brands adopt aluminium packaging. Operational efficiency reduces waste and resource consumption, including power and water, maintains production speeds and minimises downtime and overall costs. For example, on a line running 2,000 to 4,000 cans every 60 seconds, detecting and eliminating even a few minutes of defective production can dramatically reduce waste, enhance production efficiency and increase good can output.
PPG&#;s Packaging Coatings technical services team works with customers in trailing and optimising new coatings on their lines for an efficient and smooth transition. Major brands and can makers are converting to PPG INNOVEL® PRO non-BPA technology for beverage cans. The complete removal of bisphenol starting substances from food-contact coatings aligns with PPG&#;s decades-long non-bisphenol strategy. Today, the technology has coated more than 220 billion cans in 40+ countries.
This upgrade results from years of research and customer feedback to ensure improved application properties and operational benefits for plants around the globe. PPG prescribes its PPG SAFEASSURE&#; product development program for screening starting chemicals and those that could affect the packaged food or beverage to ensure new packaging technologies&#; longevity and sustainability.
More recycled aluminium plants will come online in the U.S. More brands will turn to metal packaging for its design and sustainability benefits. Coatings enhancements remain critical to enable this broader brand adoption to meet the increasing consumer demand and regulatory pressure for safe and sustainable packaging. Partnering with the right coatings solutions providers like PPG paves the way for on-trend, operationally efficient, innovative and sustainable metal packaging of the future.
About the Author
Anurag Raj is PPG&#;s Customer Sustainability Business Partner for Packaging Coatings. He is responsible for leading and supporting PPG&#;s and its customers&#; sustainability targets. PPG&#;s Packaging Coatings business creates effective coating solutions for nearly all metal packaging end-use in the beverage, food, cosmetic, and personal care industries.
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