Russell Wiseman, head of global beverage solutions, Domino Printing Sciences, explains why aluminium remains one of the top solutions for sustainable beverage packaging
As beverage brands strive to meet circular economy targets and cut carbon emissions, aluminium’s recyclability and efficiency make it an obvious choice. Unlike PET or glass, aluminium is a true closed-loop material that can be recycled infinitely without losing quality. Global aluminium recycling rates sit at around 75% – outperforming PET bottles (47%) and glass (42%) – which saves an estimated 5.4 million tonnes of CO₂ annually.
Regulation is accelerating recycling progress. Under the EU Packaging and Packaging Waste Regulation (PPWR), aluminium packaging must meet 50% recycling by 2025 and 60% by 2030. In addition, the regulation’s strict design-for-recyclability requirements are inspiring new thinking in product and packaging design. For beverage brands, aluminium isn’t just a packaging choice – it’s a compliance strategy and a reputational asset.
Speed and accuracy
But sustainability doesn’t stop at the can. Every stage of production matters, including the coding that underpins compliance and traceability at scale. Modern beverage lines often exceed 120,000 cans per hour. At this pace, coding is mission critical. Errors or issues become expensive very quickly, creating costly recalls, wasted product, and regulatory exposure. Every can must carry accurate traceability information to meet regulatory and retailer requirements.
The industry requires coding technology that supports the needs of fast-moving, sustainability-driven operations. Yet conventional inkjet systems can struggle at these speeds. The resultant excessive use of inks introduces chemical waste, undermining sustainability goals. Furthermore, the inevitable impact on production not only delays output but also adds costs.
Coding for sustainability
Recent innovations are enabling beverage manufacturers to reconsider their approach to sustainability and compliance. New high-speed, low-waste technologies, such as fibre laser coding, which delivers permanent, high-resolution codes without inks or solvents, allows manufacturers to maintain sustainability without compromising performance throughput.
Breakthrough solutions such as the Beverage Empty Can Coding System (BECCS) from Domino, moves coding upstream to the empty can stage, creating a significant contribution to waste reduction and operational efficiency. By coding before filling, manufacturers can catch errors early, preventing costly recalls and product loss.
Operationally effective
BECCS is purpose-built for high-output lines where accuracy, speed, and low waste are non-negotiable. Beyond performance, BECCS enables brands to maintain production traceability and comply with EU labelling requirements, without sacrificing efficiency.
Fibre laser technology also keeps pace with existing high-speed production performance, matching line speeds of 120,000 cans per hour. In addition, integrated vision and rejection systems provide real-time error detection, preventing faulty codes from reaching the market, reducing waste and minimising downtime. With a mean time before failure (MTBF) of up to 100,000 hours, these innovative systems also deliver exceptional reliability.
Wiseman comments, “Circularity starts long before a can reaches the shelf. Aluminium offers an infinitely recyclable foundation, but the real progress comes from rethinking every step of production – coding included. Moving traceability upstream and eliminating consumables isn’t just operational efficiency; it’s how we make sustainability practical at scale.”
Closing the loop
Aluminium cans and fibre laser coding create a powerful sustainability partnership. Together, they enable beverage brands to meet circular economy targets, reduce carbon emissions, and maintain production agility. As the industry moves toward 80% global aluminium recovery by 2030 and near-100% by 2050, technologies such as BECCS will play a pivotal role in closing the loop – ensuring that every can is coded accurately, efficiently, and with minimal environmental impact.
