The cost of manufacturing custom aluminum cans varies with the production volume, printing method, material quality, and design complexity. The global market size for aluminum packaging was $45.5 billion as of 2022 and is set to grow at a CAGR of 4.5% owing to the rising demand for custom branding, sustainability, and light-weighting packaging.
The material cost basis is a function of aluminum prices, which fluctuate based on market demand and supply chain dynamics. The average price of aluminum in 2023 was $2,400 per metric ton, which determined the cost of raw aluminum sheets for the production of cans. A 12-ounce aluminum can weighs approximately 14 grams, and hence a metric ton of aluminum can produce approximately 71,400 cans.
The manufacturing cost is dependent on the size of the order. Large-scale production through offset lithography requires minimum orders of 50,000 to 100,000 cans for a design, reducing the cost per can to $0.10 to $0.30. Small-scale production, typically utilized by craft breweries or specialty beverage brands, uses digital printing or shrink-wrapped labeling, which requires lower minimum orders of 500 to 5,000 cans but costs $0.50 to $1.50 per can.
Printing has a significant impact on costs. Offset lithography, the industry standard, prints at high rates up to 2,000 cans per minute at high economy and durability. Digital printing, which provides low-volume runs and customization of individual designs, is 30-50% more per can but without plate-making fees. Shrink-sleeve labels offer design flexibility and short-run customization but add $0.05 to $0.15 to the overall cost per unit.
Additional customization features such as matte finishes, embossed textures, or thermochromic inks increase the cost of production. For example, Coca-Cola’s temperature-changing color cans for promotion campaigns are $0.02 to $0.05 more expensive per can, while embossing costs $0.05 to $0.10 more per unit.
There is also the expense of distribution and logistics. It requires a total of 25 standard pallets to transport 100,000 empty aluminum cans, and the freight cost varies by location. Domestic shipping costs range from $0.01 to $0.03 per can, and foreign orders tack on 10-20% to prices due to import duties and fuel surcharges.
Entrepreneur Elon Musk once said, “The first step is to establish that something is possible; then probability will occur.” Businesses considering custom aluminum cans should balance order volume, printing techniques, and logistics for a perfect balance between cost and brand impact. Whether for craft breweries, energy drinks, or corporate promotions, aluminum cans offer superior recyclability, durability, and branding potential, and they are an essential packaging solution for businesses today.