In the packaging of beverages, the major difference between standard cans and regular cans is the detailed optimization of size parameters. For instance, in a capacity of 330ml. The diameter of the standard standard can is 66.2mm and the height is 123mm. Although, thin cans reduces the diameter to 57mm (13.9% reduction) through the process of cold rolling, maintains the height within the margin of error of 121mm±0.3mm, and reduces the surface area of the can by 18%. Aluminium material thickness is reduced from 0.28mm to 0.21mm. It reduces the weight of a single can from 21g to 16.5g. As calculated by Anheuser-Busch InBev’s 2023 estimation, 4.5 tons of aluminum is saved in each million cans, cutting material cost directly by 112,000 US dollars.
Technologically from a manufacturing point of view, the slim can specification breakthrough stems from the development of high-strength alloys. Orikin’s T4-T61 tempered aluminum alloy allows tank body to remain ≥90psi compressive strength and decrease 24% of wall thickness, and axial loading capacity is as high as 1,450N, or 7% above that of ordinary tanks. Dongpeng Special Drink uses 250ml chic cans. Compressed from an original 65mm, can mouth diameter now stands at 55mm. Combined with the 38° incline closing structure, the filling line speed is increased from 800 cans per annum to 1,200 cans. Filling accuracy remains at ±0.3ml, while the annual production capacity is increased by 40%.
The logistics benefits vary significantly. Thin cans’ small size increases the load density. The palletizing dimension of typical tank pallets is set in 24×24, while thin tanks are set at 28×28 since the diameter is reduced. The quantity of tanks loaded within a single 40-foot container is increased from 92,160 tanks to 129,600 tanks (an increase by 40.6%). The measured data at Coca-Cola Japan shows that following the implementation of 57mm diameter slender cans, vending machine aisle capacity increased from 120 cans to 168 cans, replenishment frequency reduced by 29%, and transportation damage rate reduced from 0.8% to 0.3%. This optimization reduces the cost of logistics per can by 0.12 yuan. Based on an annual sales quantity of 1 billion cans, it can save 120 million yuan.
The size optimization data for consumer experience are more persuasive. Based on Nielsen research, the 54-58mm diameter slim can has a one-handed grip comfort score of 8.7/10, 32% higher than that of common cans. Magic Claw Energy Drink 250ml slim can also features a 7° arc-shaped waistline design that reduces the grip friction to 2.1N from 3.2N and increases the opening pull force to 8-12 pounds (15-18 pounds in the case of the regular can). Yanki Forest’s newer 200ml sleek cans have changed the height-to-diameter ratio of the cans from 1.85 to 2.1. The size of shelf display area has decreased by 22%, whereas the visual attention rate has increased by 18 percentage points.
The data from the performance size of environment protection show slender cans are more suitable for the circular economy. The European Aluminium Institute report shows that recycling and smelting of drinks cans up to a diameter of 60mm takes 13kWh/kg, 17% less than normal cans, and recycled aluminium can achieve a purity level of 99.3%. The 500ml Carlsberg beer slim cans utilized laser coding rather than ink printing, increasing the level of recycled residual aluminium from 92.5% to 98.7% and reducing carbon emissions per tonne of recycled aluminium by 8.4 tonnes. The actual measurement of Ball Company in America shows that the size of the metal fragment after crushing the thin cans is concentrated in 2-5mm (5-10mm for regular cans), the sorting efficiency is enhanced by 37%, and the recycling rate can reach 76%.
Common situations validate size innovation’s effectiveness: Red Bull’s new 250ml ultra-slim can launched in 2023 increased one shop’s average daily sales per shop in the Walmart channel by 23% by reducing diameter from 66mm to 56mm and halving shelf turnaround time from 5 days to 3.5 days. The 350ml slim cans of Japan’s Kirin Beer employs 0.18mm ultra-thin aluminum material, expanding the capacity of the refrigerated display cabinet from 150 cans to 210 cans and saving 19% in power consumption. These facts confirm that size variations are revolutionizing the technical norms and business sense of beverage packaging.