How are aluminium drinks cans made?

Pick up a can of your favourite drink and you’re holding a quiet marvel of mass production. Every year, more than 370 billion aluminium drinks cans are produced worldwide.

It all starts with flat sheets of aluminium, often made from over 69% recycled material. These sheets are fed into a powerful press that punches out circular blanks and shapes them into shallow cups. From there, a body-making machine stretches and moulds the cups into that familiar cylindrical form, complete with a domed bottom designed to handle the pressure of carbonated drinks. Once the can is formed, any uneven metal at the top is trimmed away to create a clean and levelled edge.

But before the cans can be dressed up and filled, they need a deep clean. Lubricants and oils are used during shaping to help the metal flow smoothly through the machines. These are washed away with hot water and chemicals, prepping the surface for coatings that protect both the inside and outside.

Cans are generally distinguished by their vibrant designs and recognisable logos. A high-speed printer applies these, layering ink and sealing it with a clear varnish to keep everything crisp during transport and handling. The cans are then baked to cure the design into a durable finish. Inside, a food-safe lacquer is sprayed to prevent the drink from reacting with the metal and preserve its flavour. Another quick bake hardens this inner coat. 

Next, the can gets its signature neck and lip. To achieve this, the can is forced through a set of progressively smaller tools that gently squeeze the top inward, then flare it out to create a protruding rolled edge, where the lid will be securely fitted later. This process is done in multiple small steps as aluminium cans are very thin (less than 0.3 millimetres), so one wrong move could tear or wrinkle the cans. 

Before leaving the factory, the cans are tested to confirm strength and quality. Those that pass are shipped to manufacturers, where they’ll be filled, lidded and sent to stores.

And what about the lid? This is manufactured separately, and the process begins similarly to can bodies: aluminium sheets are pressed into round shells and curled at the edges. 

A sealing compound is added inside the curl, then baked to form a soft, rubbery ring that keeps drinks fresh. Next, a groove is scored into the lid, to make the can easy to open, and a separate tab is placed perfectly over the top, locked in place with a rivet to maintain pressure. When you pull the tab, it presses into the groove, breaking the seal and letting the fizz flow. After the drink is filled, the lid is attached using a process called ‘double seaming’, which ensures an airtight leak-proof seal.

The result is a can that’s strong, light, and endlessly recyclable. Aluminium drinks cans are the most recycled packaging in the world. In fact, your empty can could be back on the shelf as a new one in as little as 60 days.