Alcoa, Ball and Unilever pioneer carbon-free aluminum manufacturing for consumer packaging

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Image credit: Ball Corporation

Alcoa Corporation, in partnership with Ball Corporation and Unilever PLC, has announced the first use of ELYSIS carbon-free smelting technology in the manufacturing of consumer personal and home care packaging. 

According to Alcoa, the ELYSIS technology eliminates all direct greenhouse gas emissions from the aluminum smelting process by generating oxygen instead of carbon dioxide. 

The ASX-listed company said the resulting aerosol can – produced using 50 per cent ELYSIS primary aluminum and 50 per cent post-consumer recycled content – represents one of the lowest-carbon packaging solutions currently available.

“Through this collaboration with Ball and Unilever, we’re helping bring low-carbon aluminum into everyday products and demonstrating how innovation at the material level can deliver tangible sustainability benefits,” said Renato Bacchi, Executive Vice President and Chief Commercial Officer at Alcoa. 

“We are proud to collaborate across the aluminum value chain to reduce carbon footprints and create real impact in people’s daily lives.”

The initiative precedes the 30th United Nations Climate Change Conference (COP30), a global forum where governments, industries and research bodies will convene to discuss strategies for mitigating climate change. 

Alcoa said the collaboration underscores the importance of cross-sector partnerships in advancing carbon reduction technologies.

Ball Corporation’s Chief Sustainability Officer and Vice President of Public Affairs, Ramon Arratia, said the joint project exemplifies both packaging and supply chain innovation. 

“This project combines higher recycled content and low-carbon primary aluminum – both key to decarbonize aluminum packaging and the aluminum sector at large,” he said. “This is both a packaging innovation and critical supply chain collaboration at work.”

According to Alcoa, Unilever’s participation further extends the initiative’s reach into consumer markets, demonstrating the potential of carbon-free aluminum manufacturing to reduce the environmental impact of everyday household and personal care products.

Alcoa stated that the introduction of ELYSIS aluminum into consumer packaging highlights how technological advancements in manufacturing can align with global decarbonization goals and growing consumer demand for sustainable products.

For more information, visit www.elysis.com.

The content of this article is based on information supplied by Alcoa Corporation. For more information, please refer to the official company announcement and communications from Alcoa. Please consult a licensed and/or registered professional in this area before making any decisions based on the content of this article.