Contact Sales on +44 (0)1472 240940
Berlin Packaging expands its presence in EMEA with the acquisition of BlueSky.
Contact Sales on +44 (0)1472 240940
Berlin Packaging expands its presence in EMEA with the acquisition of BlueSky.
But many businesses assume custom aluminium packaging is only realistic at very high volumes.
That is not always the case.
At BlueSky, selected stocked aluminium bottles can be custom printed from as little as 1,000 units, making branded aluminium packaging more accessible for product launches, limited editions, seasonal campaigns and growing brands testing a new format.
This guide explains how custom aluminium bottle printing works, what affects lead times, what decoration options are available and what to consider before starting a project.
Yes, aluminium bottles can be custom printed using decoration methods such as base colour coating, screen printing and other specialist finishing techniques.
With BlueSky, selected stocked aluminium bottles can be printed from 1,000 units, with a typical lead time of 4–6 weeks from proof sign-off to delivery, depending on the project specification.
Custom printing is suitable for brands that want a more distinctive pack without immediately committing to very high manufacturing volumes.
Aluminium bottles give brands a highly visual, tactile and practical packaging format.
Unlike clear packaging, aluminium does not rely on the product inside to create shelf appeal. The entire bottle surface can become part of the brand identity, from the base colour and finish through to the logo, product name, claims and design details.
This makes aluminium especially useful for brands that want to:
For beverage brands, aluminium can help create a lightweight and shatterproof format with strong visual impact. For personal care, wellness and beauty brands, it can support a premium, modern or more technical aesthetic.
One of the biggest advantages of working with BlueSky is overcoming the extremely high minimum order quantities manufacturers have.
For selected stocked aluminium bottles, BlueSky can support custom printing from 1,000 units.
This is particularly useful for:
A lower MOQ allows brands to explore custom aluminium packaging without the risk of committing to a large production run before the market has been tested.
For larger or more complex projects, additional options may be available at point of manufacture, depending on the specification, artwork and required volume.
Custom aluminium bottle printing follows a structured process to make sure the finished pack is accurate, durable and commercially viable.
1. Choose the bottle format
The first step is choosing the aluminium bottle size, shape, neck finish and closure combination.
This decision should be based on the formulation, filling method, application, sales channel and brand positioning. A 5cl drinks bottle, for example, will have different requirements from a 500ml personal care bottle or a 1-litre home care product.
2. Submit your artwork
The process begins with your vision. A proof is devised from your artwork to ensure the brief and expectations are fully met.
3. Review and approve the proof
Once you approve the final design, production is scheduled. This step provides a key planning parameter: a predictable turnaround of 4-6 weeks from proof sign-off to delivery.
4. Prepare the bottle surface
The bottle’s surface is prepared with a flame-treatment and spraying. Custom tooling templates are created to ensure precise artwork alignment.
5. Print the design
The design is not applied all at once. Instead, each individual colour is carefully applied using precise screen printing techniques for a crisp, vibrant result.
6. Cure and quality check
Finally, the printed bottle is heat-cured to lock in the design and maximise durability. A thorough quality check with various tests is performed to ensure every bottle meets the highest standards.
Custom aluminium bottle decoration can include several different approaches depending on the desired finish, artwork and order volume.
Common options include:
| Decoration option | What it does | Best suited to |
|---|---|---|
| Base colour coating | Applies a colour across the bottle surface | Full-brand colour impact |
| Screen printing | Prints artwork, logos and text onto the bottle | Bold designs and durable branding |
| Matt finish | Creates a softer, more premium surface effect | Beauty, wellness and premium products |
| Gloss finish | Creates a brighter, more polished look | FMCG, beverage and high-impact designs |
| Pantone colour matching | Supports brand colour consistency | Established brands with strict guidelines |
For many brands, the strongest result comes from combining a base colour coating with screen-printed artwork. This turns the whole bottle into a branded pack rather than simply placing a logo onto a standard container.
For selected stocked aluminium bottles, BlueSky typically works to a lead time of around 4–6 weeks from proof sign-off to delivery.
The exact timeline depends on:
Using UK-held stock can help simplify the process because the base bottles are already available before decoration begins. This can be especially valuable for brands working to launch dates, retailer deadlines or seasonal campaigns.
Custom packaging can become complicated when every part of the project depends on overseas production, high MOQs or long manufacturing lead times.
Using stocked aluminium bottles gives brands more flexibility.
BlueSky’s UK stock model can help brands:
This is particularly useful for growing brands that need professional, branded packaging but do not yet want to commit to full manufacturing volumes.
Before starting a custom aluminium bottle printing project, brands should consider both the creative and technical requirements.
Key questions include:
Considering these points early helps avoid delays and makes the final pack more commercially effective.
Custom printed aluminium bottles are suitable for a wide range of sectors.
Beverage
Aluminium bottles can be used for spirits, wine, water, functional drinks, mixers and travel-friendly formats. They are lightweight, shatterproof and highly distinctive on shelf.
Personal care and beauty
Aluminium bottles can support products such as lotions, mists, hair care, body care, fragrance and wellness sprays. The material gives a premium finish and strong shelf presence.
Home care
Aluminium bottles can be used for surface sprays, concentrated cleaning products, refill-led home care ranges and premium household products.
Health and wellness
Aluminium bottles can support wellness sprays, supplements-adjacent products and formats where a more premium or protective pack is required.
Yes, custom printed aluminium bottles can be suitable for smaller brands, especially when using stocked bottles and lower MOQ decoration options.
The key advantage is that brands can create a professional printed pack without needing to commit to tens of thousands of units from the start.
This makes custom aluminium bottle printing useful for:
For many brands, it provides a practical route into premium packaging without the usual scale barriers.
BlueSky helps brands source, specify and decorate aluminium bottles for a wide range of product applications.
The team can support with:
Whether you are launching a new product, testing aluminium for the first time or developing a more distinctive branded pack, BlueSky can help you move from idea to finished bottle.
Contact us today:
Horizon House
Estate Road Five
Grimsby
DN31 2TG
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