Sustainable Metal Packaging Solutions for Food and Drink
Sustainability has emerged as a leading topic in the packaging industry. With increasing public awareness regarding plastic waste and environmental taxation measures like the Plastic Packaging Tax (PPT), businesses, retailers, and consumers are revisiting their packaging strategies.
But what makes metal packaging a sustainable option? With over 50 years in the packaging sector, Invopak explores the environmental benefits of metal packaging and highlights why a material that is infinitely recyclable aligns perfectly with packaging sustainability.
Types of Metal Packaging
Every packaging material must fulfill two fundamental criteria: it should be practical for its intended use and cost-effective. For example, while a food can could be made from gold, the cost impracticality and softness of the metal make it an unsuitable choice.
The metal packaging industry is largely dominated by steel and aluminum. Both are abundant, making them relatively inexpensive options. Moreover, steel and aluminum possess the ideal physical properties for packaging: they are malleable, non-toxic, and exceptionally durable.
Aluminum
Aluminum’s unique properties render it ideal for packaging applications. It is non-magnetic, non-sparking, malleable, lightweight, and corrosion-resistant—ensuring it does not rust in water, which is particularly important for liquid storage.
Aluminum is also highly sustainable; no matter how frequently it is recycled, its quality remains intact. It is recognized as one of the most valuable materials discarded, leading to a robust incentive for recycling. The recycling of aluminum is so valuable due to the high costs associated with mining it. The extraction process from bauxite ore utilizes electrolysis, which is energy-intensive. In contrast, producing cans from recycled aluminum consumes 95% less energy than processing primary aluminum.
Aluminum’s non-magnetic nature allows it to be efficiently separated from other types of waste using electrical current. Once collected, it’s shredded, heated to eliminate any remaining paint, melted down, and recast into ingots.
Recycling aluminum is remarkably quick and straightforward. Recycled aluminum drink cans can be processed and back on supermarket shelves in just 60 days. Additionally, unlike many plastic items, 90% of the aluminum packaging consumed in the UK is recycled within Europe, eliminating the need for long transport distances.
Drink cans represent the most prevalent form of aluminum packaging, with 180 billion produced globally each year. This range extends beyond soft drinks to include beer, cocktails, wine, and iced coffee.
Aluminum bottles are excellent options for packaging liquids, including perfumes, available in sizes ranging from 19ml to 12.5L and everything in between.
Steel
Mild steel comprises 99% iron, making it one of the most abundant and commonly mined metals globally—representing 94% of the metal extracted worldwide. Its abundance leads to its status as the cheapest metal available. Furthermore, the ease of extraction and refinement makes steel ideal for large containers such as steel drums.
Steel is also among the most recycled metals. In fact, 85-90% of steel products are derived from recycled steel, reinforcing its appeal as a sustainable packaging material.
Practically, steel offers durability and cost-effectiveness for storing significant quantities of petroleum, oils, and liquids. Steel drums are specifically designed for bulk shipping, manufactured from cold-rolled steel that is formed into tubes, seam-welded, and fitted with a bottom to create a drum.
Open-head drums feature a ring latch closure and can contain anything from paints and powders to liquids and oils. Tight-head drums come with specialized bung closures for liquid and oil storage.
Steel kegs can have either lacquered or plain interiors. It’s worthwhile to note that solvents can be safely stored in standard unlacquered barrels due to their non-reactivity with steel, whereas water-based products are better stored in lacquered containers to prevent corrosion.
Furthermore, steel drums and barrels are not only durable but can also be cleaned and reused. Reconditioned steel drums serve as an economical and sustainable choice.
Tin
Tinplate packaging comprises a core of steel adorned with a thin layer of tin to prevent rusting. This packaging boasts an exceptional strength-to-weight ratio, making it economical to produce and easily recyclable post-use. Manufacturers can press, roll, print, and weld tinplate into virtually any desired style, shape, or size of packaging.
As one of the oldest packaging solutions, tinplate’s inception can be traced back to Napoleon Bonaparte. He sought efficient food preservation for his army, offering 12,000 Francs for a solution, leading to the creation of the tinplate food can.
Tinplate remains among the most widely used types of metal packaging today. Its cost-effectiveness makes it perfect for storing paint, while pails and drums are ideal for holding resins, oils, coatings, and powders.
Moreover, this material is suitable for photographic-quality color printing. The offset printing technique enables the application of vibrant, high-quality graphics directly onto the tinplate sheets before they are shaped into containers. This feature proves particularly beneficial for high-volume users seeking to elevate their products on store shelves.
Notably, tinplate is 100% recyclable, and the economics of tin recycling are favorable as well. Recycling one tonne of tin conserves 99% of the energy required for its primary production. All tinplate containers can undergo recycling, even if they previously held paint, since any residual coatings are neutralized during incineration as part of the recycling process.
The International Tin Association reports an average recycled content of 33.1% in tin products. This underscores that nearly one-third of the material used in new paint tins has already served a previous purpose.
For decades, Invopak has excelled as a metal packaging wholesaler, and in 2024, we expanded to manufacturing. Our Invopak tinplate factory situated in Manchester is now producing highly sought-after tinplate products, which includes lever lid tins.
Advantages of Metal Packaging
Durability and Practicality – Metal stands as the strongest packaging material available. Unlike glass, it does not shatter and offers high puncture resistance, making it impermeable and suitable for heavy loads.
100% Recyclability – Metals are permanent materials that can be reused indefinitely without any degradation in quality. In a world increasingly focused on sustainability, metal presents one of the most effective packaging solutions.
Simple Recycling Process – Metal packaging consists solely of one material, streamlining the recycling process. For instance, drink cans and paint tins are made from aluminum or steel, requiring no separation of different materials. The process is as easy as collecting, melting, and reusing—it’s that uncomplicated with metal.
Tried, Tested, and Trusted – Stakeholders in both business and consumer sectors trust metal packaging. For decades, metal paint cans and food containers have demonstrated their reliability and safety in storing and transporting a diverse array of products.
Quality and Prestige – Consumers often equate metal with superior quality. Businesses can command higher prices for products packaged in metal. Premium paint brands leverage tinplate tins to convey prestige, and the beverage sector has notably benefited from using full-color printed aluminum cans to distinguish themselves in a competitive market.
Transition to Sustainable Metal Packaging
As consumers grow increasingly aware of the environmental implications tied to packaging choices, the stark environmental repercussions of single-use plastic bottles are becoming impossible to ignore, particularly when one considers their abundance in landfills and oceans.
In response, many large retailers are shifting towards metal packaging, providing refillable aluminum bottles for cleaning and laundry products, recognizing that customers are enthusiastic about leading more sustainable lifestyles.
Additionally, numerous suppliers are transitioning from plastic to metal for economic reasons. Environmental taxes, such as the Plastic Packaging Tax (PPT) and Extended Producer Responsibility (EPR), focus on discouraging plastic use by imposing higher tariffs on plastic products. These taxes are set for annual increases as the government aims to diminish our reliance on plastic.
Selecting metal packaging sends a compelling message to your customers about your commitment to sustainability. Why delay the switch to metal?
Sustainability for the Long Term
When it comes to recyclability, metal remains unchanged. As a permanent material, its structural integrity is maintained, regardless of how many times it has been processed. Metal is just as recyclable today as it was 1,000 years ago.
While plastic can be recycled, it often loses some of its physical properties during this process. This results in plastic being trapped in a downcycling cycle that ultimately leads to incineration or landfilling. Similarly, paper and cardboard packaging, often touted as sustainable alternatives, also lose quality during recycling and rely on a continuous supply of wood to maintain primary stock levels.
Metal remains unparalleled when considering long-term sustainability.
For further information, please visit https://invopak.co.uk/
