Metal Can Lightweighting

Cost Optimization, Packaging Optimization, & Value Optimization

Client Needs

Lightweight the metal can used for snack products to reduce packaging material and cost while maintaining product integrity and operational performance across existing lines.

The Challenge

Confirming lighter-gauge can performs equivalently during filling/sealing/distribution; coordinating a production trial in a narrow transition window; obtaining historical testing data.

Our Approach

  • Collaborated with the can supplier for prior test data 
  • Developed a qualification plan for the lighter-gauge can once inventory depleted 
  • Aligned plant resources and arranged on-site supplier monitoring; assessed line performance and seam quality in real time

The Impact

  • Over $500K estimated annual cost savings from material reduction across can-packed SKUs 
  • 100% successful qualification with no disruption to filling/seaming 
  • Supports company-wide sustainability initiatives

Let’s Talk Efficiency Gains

Want to reduce production costs, increase throughput, or optimize your packaging line? Let’s connect.

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