Why Aluminium Represents a Sustainable Packaging Alternative

A report published earlier this year by Metal Packaging Europe and European Aluminium revealed the recycling rate for aluminium beverage cans in the European Union, United Kingdom, Switzerland, Norway and Iceland was 74.6%.

In a bid to adhere to upcoming EU regulations, many companies are doing away with plastic packaging in favour of the more sustainable aluminium, thus contributing to more resilient supply chains.

While some companies are put off by high prices and potential impact on their image, others are keen to join the movement and get ahead of competitors. 

A packaging alternative

The aforementioned report states that the total amount of aluminium recycled from cans reached a reported record high of 580,000 tonnes in 2024 – an increase of 10,000 tonnes. The result was a greenhouse gas (GHG) saving of 5.4m tCO₂e.

In January 2030, new EU waste regulations are due to come into effect, mandating that all packaging should be at least 70% recyclable, increasing to 80% by 2038.

The measure aims to reduce packaging waste by introducing more reuse and refill systems, as well as decrease the use of raw materials in packaging.

As a result, many companies are making the switch to aluminium packaging, trialling it in toiletries, condiments and wines. 

According to the National Packaging Waste Database, the recycling rate of aluminium cans stands at 81%, as opposed to the 52% of plastic. The metal is considered to be infinitely recyclable. 

Innovative designs

Meadow, a Swedish packaging startup, was founded in 2020 with the aim of replacing single-use packaging.

It is dedicated to using pre-existing factors, from established supply chains and product familiarity to established recycling infrastructure. This way, it can dedicate itself to true circularity.

Meadow has redesigned the aluminium can to slot into sustainable cannisters, which can be equipped with pumps, squeeze tops, spray nozzles and screw top lids.  Once the can is empty, it can be removed for recycling and replaced with a new one. 

Victor Ljungberg, Meadow's Co-Founder and CEO, explains: "We realised the greenest container already exists – the aluminium can. So, we thought, 'what do we need to do to take it to new industries?'"

Ball Corporation, the global aluminium manufacturer, has invested in Meadow and will supply cans which will be used in Meadow's reusable dispensers. 

Elsewhere, food innovation brand DOZZ is introducing ready-to-eat chilled soup in an aluminium can that can be recycled once the food is consumed. 

In the wine industry, companies are turning to aluminium over glass bottles. Crucially, the metal is lighter than glass, meaning the energy required to transport products is significantly lower.

Aldi has launched an own-label wine in an aluminium bottle, while organic brand Vinca has been selling its 75cl bottles in Tesco. 

Supply chain barriers

While the switch to aluminium makes plenty of sense, many companies remain reluctant. 

Production can be costly. Despite being roughly one third lighter than glass, saving 900 grams of CO₂e, new aluminium requires twice as much energy during the production process and is four times more expensive.

"We've got to get over this cost," asserts Mark Lansley, CEO of Broadland Drinks. "We've got to sell the benefits and better spell out the lower carbon footprint that aluminium has.

"Aluminium bottles are lighter and don't shatter, so they are much better for a picnic or by the pool. But then you've got tradition and what folks are used to. You might be opening a bottle of wine to celebrate with friends or as a reward and relaxation. A glass bottle of wine is embedded in that culture."

Moreover, some products, such as condiments or washing up liquids, rely on squeezable plastic bottles.

Jamie Stone, a packaging expert at PA Consulting, adds: "In many categories, consumers want to see the product they're buying, whether it's the colour of a juice, the consistency of a lotion or the thickness of a sauce. Aluminium's opacity removes that visual connection."

Whether more brands adopt aluminium will become clearer as the EU regulations deadline approaches, but companies like Meadow are certainly ahead of the curve when it comes to packaging innovation.