Beverage Production 101: Six Must-Know Facts About Cans!

Beverage Production 101: Six Must-Know Facts About Cans!

Aluminum cans are taking the beverage world by storm! This trendy packaging option is projected to skyrocket the global aluminum cans market to an astounding $87.1 billion by 2030, up from $54.3 billion in 2021, boasting a fantastic compound annual growth rate (CAGR) of 5.39%! As consumers increasingly seek out eco-friendly and sustainable choices—especially with the growing backlash against single-use plastics—aluminum cans have stepped into the spotlight as the go-to choice for countless beverage brands. Both environmentally conscious customers and companies are thrilled by the incredible recyclability and reusability of aluminum, making it a win-win for everyone involved!

Did you know that the Environmental Protection Agency (EPA) reports that in the U.S., a fantastic 34.9% of aluminum containers and packaging get recycled? That's right! And guess what? Over half of those recycled aluminum items are actually beer and beverage cans! How cool is that? Plus, these cans are super convenient and easy to carry, making them perfect for our busy, active lifestyles. Cheers to sustainability and on-the-go refreshment!

With the rising popularity of cans, it’s crucial to grasp a few key insights before deciding if they’re the right fit for your drink! Your knowledge about the can industry, how cans are made, and the sourcing methods can greatly influence both the cost of your beverage and how quickly it hits the shelves. Here are seven exciting things you need to know about canning your beverage!

1. Lead Times Can Be Long and Fluctuate Throughout the Year

Lead times are absolutely crucial for your beverage business! If you don’t factor in enough lead time, it can completely derail your production and launch plans, not to mention hike up your costs! With only a handful of can suppliers available, your options become pretty limited when lead times start to shift—something that happens quite often throughout the year! Just imagine this: we’ve seen lead times for 8.4-oz cans soar from the usual six to eight weeks all the way to 16 weeks in no time at all! And during the summer months, which is peak beverage season, lead times can really stretch out due to new packaging trends or those massive orders you’re excited to fill! So keep an eye on those lead times; they can make all the difference in your success!

To ensure that unexpected lead times don’t throw a wrench in your production schedule, it’s crucial to actively manage your timeline and, if you can, maintain an extra month’s worth of inventory—particularly during the bustling spring and summer seasons! And let’s not forget about the power of communication with your supplier! By consistently sharing updates about your anticipated demand, you empower your supplier to keep you in the loop about any changes that could affect product availability. This proactive approach can make all the difference in keeping your operations running smoothly!

2.Minimum Order Quantities Are Higher Than You Might Expect

Many can suppliers stipulate a minimum order quantity of an entire truckload when it comes to printed cans. The exact amount for a full truckload (FTL) can differ based on the can size. For instance, the minimum order quantity (MOQ) for a standard 12-ounce can is 204,225 units, which corresponds to 8,509 cases of 24 packs. If you're unable to fulfill that minimum requirement, you can choose to purchase pallets of brite cans from a broker or reseller and customize them. Various decorating options for brite cans are quite popular, including:

• Pressure-sensitive labels (PSLs): These labels feature an adhesive layer that necessitates the application of pressure to adhere properly to the surface of the product.
• Shrink sleeves: These are plastic sleeves that come pre-printed and conform snugly around a can when heated, offering complete coverage, outstanding durability, and vibrant graphics.
• Digital printing: This innovative technology enables the direct application of digital designs onto the surface of cans. It offers a wide color palette and accommodates images of different quality levels.

While this approach enables you to purchase smaller quantities of cans, it's crucial to recognize that the cost per unit is usually significantly higher than that of printed cans. The extent of this price difference varies based on the type of sleeve and its design, but generally, you can expect an additional cost of $3 to $5 per case for sleeving compared to printing directly on the cans.

Moreover, beyond the cans themselves, you need to factor in the expenses for the sleeves, their application, and the shipping costs to transport the cans to your sleever and ultimately to your destination. In most cases, you will be required to arrange full truckload shipping since can pallets are typically too large for less-than-truckload (LTL) carriers to accommodate.

Unlike sleeves, which have been utilized for many years, digital printing on cans is a relatively recent advancement. The higher expenses associated with digitally printed cans stem from factors such as lower minimum order quantities, slower production rates, and the need for specialized inks and equipment. However, as the technology continues to develop and production increases, it’s possible that the costs of digital printing will decrease over time.

An alternative approach is to purchase a full truckload of pre-printed cans and store them for later use. However, this option comes with its own challenges, including warehousing costs and the limitation of making artwork modifications between production runs. Consulting with a beverage packaging specialist can assist you in optimizing your order strategy for future needs.

Understanding your financial limits and maintaining a precise projection will enable you to make choices that are in harmony with your business objectives. As you consider your options, weigh the advantages and disadvantages of various packaging solutions. Although opting for the cheapest alternative might seem appealing, it's worth exploring more adaptable options like digital printing or sleeving, depending on your needs.

While these alternatives may incur higher costs per unit, they typically come with lower minimum order quantities (MOQs) and quicker turnaround times, providing greater flexibility to adjust to unpredictable sales patterns or shifts in demand.

3. Availability May Be an Issue

When you require a specific can style or size, it is often urgent. Beverage manufacturers typically cannot afford the luxury of waiting six months for their cans, given tight production timelines and product launch schedules. Unfortunately, some can sizes are produced erratically or only a few times each year, leading to prolonged shortages of certain models and sizes.
Moreover, if a production line for a particular can experiences downtime or if there’s an unexpected surge in interest for a new can design, availability may become constrained. For instance, a sudden increase in demand for Monster Energy drinks could create pressure on the supply chain to ensure there are enough 16-ounce cans available.

To minimize problems with availability, it’s crucial to anticipate needs and stay informed about trends and advancements in beverage packaging. Whenever feasible, incorporate time and adaptability into your strategies. In periods of potential shortages or limited supply, maintaining a strong rapport with your can supplier and co-packer can provide valuable insights, keeping you informed and ready for future challenges.

4. Colors on Cans Look Different

The brand of your drink is an important resource that requires careful planning and consistent upkeep in your marketing and packaging efforts. Although many individuals and designers are accustomed to standard four-color process printing, the approach used for cans is quite distinct. In four-color process printing, individual layers of cyan, magenta, yellow, and black are applied to a surface, with additional colors achieved by overlapping these layers or incorporating a specific spot color or PMS color.

When printing on cans, all colors need to be applied simultaneously from a single plate. Since colors cannot be mixed during the can printing process, you are restricted to using a maximum of six spot colors. Achieving accurate color matching on cans can be particularly challenging, especially with lighter shades. Given the complexity of can printing, collaborating closely with vendors who have expertise in can artwork and its specific requirements is crucial before placing an order. Additionally, it is strongly advised to participate in color proofing and press checks to confirm that the final printed cans meet your expectations prior to the commencement of full aluminum can production.

5. Not Just Anyone Is Good at Can Artwork and Design

The design and artwork of your cans are just as crucial as the colors used. An effective can designer should know how to properly trap and isolate your artwork. Trapping involves creating a tiny margin (typically three to five thousandths of an inch) between colors on the can to prevent them from overlapping during the printing process, which is essential since aluminum cans do not absorb ink. As the printing occurs, the colors naturally spread and fill in these gaps. This technique is a specialized skill that not all graphic artists may possess. You have the freedom to collaborate with any graphic designer on aspects such as design, positioning, labeling requirements, and regulations, provided that they ensure proper trapping and adherence to the correct die lines. If your artwork and design are not configured accurately, the final product may not meet your expectations. Investing in professional design expertise is preferable to risking financial loss on a printing job that fails to effectively represent your brand.

7. Liquids Must Be Tested Prior to Can-Filling

Before liquids are placed in cans, they must go through corrosion testing. This assessment identifies the necessary can lining for your drink and its expected durability. Manufacturers of aluminum cans, along with many contract packers, require a warranty for the can prior to the production of your beverage. Typically, corrosion tests yield warranties ranging from 6 to 12 months. It's important to recognize that certain beverages may be too corrosive for aluminum packaging. Factors contributing to a beverage's corrosiveness include acidity, sugar levels, color additives, chlorides, copper content, alcohol presence, juice content, CO2 levels, and preservation techniques. Conducting the appropriate tests in advance can help avoid delays and reduce costs.

The better you grasp the specifics of different container types, the simpler it becomes to choose the one that suits your requirements. Whether you opt for aluminum cans, glass, or plastic, possessing industry knowledge and insights is crucial for crafting and implementing a successful strategy for your beverage.

Beverage Cans and Bottles Sourced by Creative Package

Are you prepared to explore packaging choices for your beverage? We’re here to assist! As a prominent distributor in the beverage packaging sector, Creative Package has established strong partnerships with leading suppliers, enabling us to achieve cost-effective purchasing and ensure a dependable supply. Whether you require aluminum cans or various types of bottles, we can help you identify the ideal solution for your project and will source the finest packaging available.

Regardless of how large your order is, collaborating with us for your beverage can sourcing guarantees you a tailored experience. Whether you need cans for beer, seltzer, or soda, we assist you in selecting the ideal can based on your beverage’s contents, including testing the linings with our certified equipment. Additionally, we partner with you to find options for customizing cans that effectively represent your brand.

Embark on your quest for the ideal packaging solution for your drink! Reach out to our experts in beverage development and share your project details with us now.