3004 aluminum is utilized by 95% of the world’s cans of carbonated drinks, consisting of a manganese (1.0%-1.5%), magnesium (0.8%-1.3%) and aluminum matrix alloy mix, Exhibits tensile strength of 270-310 MPa and still has elongation of 6%-16%. According to the International Aluminum Association, the alloy claims 82% of the production market share in tanks, commands a price lower than 5052 alloy by 15% (around $2,750 / ton), and has improved stamping efficiency by 22%. According to Ball Corporation production line data, an alloy 3004 supplier to Coca-Cola, one is able to reduce the typical tank wall thickness of a 330ml unit to 0.24mm, that are 12% less aluminum compared to 0.28mm specification standard and reducing per tank cost by 8%.
3004 aluminum alloy (type of aluminum in soda cans) is processed using H19 hardening state during the manufacturing process, and yield strength is upgraded to 240-285 MPa, achieving the tank pressure standard ≥620 kPa. Crown Holdings has experimentally determined that the alloy can be drawn bottom way with 35 percent deformation without cracking, which is a 9 percent rise above that required for alloy 3104. Its unique Mn/Mg solid solution strengthening allows the expansion rate of pressurized canned carbonated soft drinks at pressure of 4.2 bar to be controlled to within 0.3%, and thus provides for a shelf life of 18 months.
Cost-benefit analysis shows that the recycling rate for this form of aluminum (3004) in soda cans is 73%, and the energy required when smelted using recycling is merely 5% of primary aluminium. Novelis’ closed-loop recycling process re-melts and re-makes tank waste, reducing CO₂ emissions by 4.2 tonnes per tonne of recycled 3004 alloy produced. In 2023, Pepsi announced that its North American plant reduced the carbon footprint of a single can from 138g to 92g through the use of 3004 alloy with 40% recycled content, reducing emissions by 230,000 tons per year.
in physical properties, thermal conductivity of 3004 aluminum alloy (soda can type of aluminum) is 209 W/m·K, and uniformity standard deviation of heat distribution in pasteurization (72°C/15 minutes) is only ±1.2°C. Its anodic oxide film thickness of 2-4μm with epoxy resin coating (5-8μm), so that corrosion resistance is more than 24 months, salt spray test up to 720 hours without perforation. The research conducted by Daiwa Canning in Japan shows that the corrosion rate of the alloy per annum in the pH 2.5-4.0 acidic environment is less than 0.02mm, which precisely matches the chemical nature of carbonated beverages.
Market application examples show that Red Bull 250ml slim tank uses 3104/3004 alloy composite structure (same aluminum type used for soda cans), through the differential thickness design (tank body 0.205mm/tank bottom 0.285mm) while maintaining the same pressure performance as an equivalent tank weight saving of 13%. The design increases the line speed to 2,800 cans per minute, a 19% increase over typical production lines, and doubles die life to 1.5 million stamping runs. In 2023, the technology will allow Red Bull to save $42 million in aluminum costs at its global production plants.
Among industry trends in innovation, Alcoa’s Evolve 3004+ aluminum grade for cans of soda contains iron at 0.15% and recycled content at 75%, with tensile strength still ≥285 MPa. Its new Texas plant opening in 2024 will reduce seven tank rolling processes to five, reduce rolling forces by 18%, and increase annual capacity by 1.2 million tons. The technology has also been included in AB InBev’s 2030 Sustainable Development Goals and is expected to reduce overall supply chain cost by 6.5%.
Data from recycling systems report closed-loop recovery rate of 3004 aluminum alloy (type of aluminum utilized in soda cans) at 63.4% in the United States and 74.5% in Europe. Statistics presented by the Ardagh Group show that 14,000 kWh of power and the equivalent of 11 tonnes of CO₂ emissions can be saved for each tonne of 3004 alloy tank recycled. With the application of magnetic separation-eddy current separation technology, its German facility has increased tank recovery purity to 99.98% and reduced the melting loss rate from 4.2% to 0.8%.