The recycling of recyclable aluminum cans is a highly efficient and sustainable process, allowing used cans to be recycled and returned to the shelves in as little time as 60 days. With an average global recycling rate of over 70%, aluminum is one of the most ecologically friendly and economically sound of all the packaging materials. The United States alone recycles more than 105 billion aluminum cans annually and, in the process, conserves an estimated 14,000 kWh of energy per ton of recycled aluminum, which is sufficient energy to power an average household for over a year.
Collection and sorting is the first step in recycling aluminum recyclable cans. Consumers dispose of used cans through curbside recycling programs, deposit return systems, or recycling centers at industrial scales. The majority of regions with deposit return systems recycle more than 90% because of the economic benefits of disposing of the cans appropriately. Automated conveyor belts and strong magnets at material recovery facilities (MRFs) separate aluminum from the other recyclables, yielding a contaminant-free aluminum stream.
Following sorting, aluminum cans are shredded and de-coated to remove any remaining labels, inks, or polymer linings. Shredded aluminum is fed through rotary kilns at temperatures exceeding 500°C (932°F). The high heat burns off organic residues, leaving clean aluminum flakes to be melted.
The melting process occurs in large furnaces on a huge scale at a temperature of about 750°C (1,382°F). Here, molten aluminum is created and then chemically refined to remove impurities. Recycling aluminum requires 95% less energy than primary production of aluminum from bauxite ore, and it is among the most energy-conserving recycling processes. Recycling one ton of aluminum saves 10 metric tons of CO₂ emissions, which reduces the carbon footprint of beverage packaging significantly.
Once purified, the molten aluminum is cast into rolling slabs or ingots, which can weigh up to 27 metric tons each. The slabs are rolled out into thin sheets of aluminum measuring between 0.097 mm and 0.115 mm in thickness, which will ultimately be used to make new cans. There are also firms such as Novelis, Ball Corporation, and Crown Holdings that produce high-recycled-content aluminum sheeting, which ensures that new drink cans have a high percentage of post-consumer recycled material.
Can production and redistribution is the final process step. Aluminum sheeting is fed into high-speed pressing and forming equipment with the ability to produce more than 2,000 cans per minute. Once formed, cans undergo quality control inspections, sterilization, and filling, and are shipped back to retailers. The ability of aluminum to be recycled and reused endlessly without losing its properties makes it one of the most significant components of the circular economy, with over 75% of all aluminum ever produced still in use today.
Governments and businesses worldwide continue to push for higher rates of aluminum recycling. The European Union has aimed for an 80% recycling rate for aluminum by 2030, and major brands like Coca-Cola and PepsiCo have pledged to use 50% recycled aluminum in their packaging by 2025. Advances in ultra-thin aluminum alloys and biodegradable coatings further improve sustainability while reducing the amount of raw material required for can manufacturing.
The advanced recycling system of aluminum recyclable cans has placed aluminum among the most efficient, cost-saving, and environmental-friendly packaging materials. For more details on aluminum recycling and market trends, go to aluminum recyclable cans.