How Aluminium Bottles Are Made

Aluminium bottles are rapidly becoming a go-to choice for brands in personal care, beverage, and wellness industries – thanks to their lightweight, durable, and infinitely recyclable nature. But how exactly are they made?

Let’s take a behind-the-scenes look at the fascinating step-by-step journey from raw aluminium slug to finished, printed bottle.

1. Starting with the Slug

Production begins with a small disc of aluminium called a slug, made from a mix of virgin and recycled aluminium. This blank will be cold-formed into a bottle.

2. Cold Extrusion

The lubricated slug is placed in a press and forced through a die – a process known as cold extrusion – to create a seamless cylindrical bottle body.

3. Trimming

The extruded bottle’s top edge is trimmed to ensure a clean, even finish, ready for further processing.

4. Cleaning and Drying

Next, the bottles are thoroughly washed and dried to remove any oils or residues left from forming, preparing the surface for coating.

5. Internal Coating

A protective inner lacquer (typically epoxy phenolic or polyester-based) is applied and then cured in a drying oven, protecting the contents and ensuring product compatibility.

6. Base Coating and Decoration

An exterior base coat is applied to ensure ink adhesion. The bottle is then decorated using indirect printing (and optionally silk screen printing) for vibrant branding and design finishes.

7. Transparent Overlacquering

To protect the print, bottles are overlacquered with a transparent coating – glossy or matte – enhancing both durability and appearance.

8. Necking and Base Shaping

Through a multi-step necking process, the top of the bottle is gradually shaped into a narrow opening suitable for capping. A concave base is also formed for stability.

9. Inspection and Packing

Each bottle undergoes a strict quality check. Once approved, it’s packaged and prepared for delivery – ready to be filled, sealed, and sent to market.

The production of aluminium bottles is a fascinating process that marries advanced technology with sustainability. Starting from a simple aluminium slug, a series of intricate and carefully controlled steps are performed to transform it into a sleek, lightweight, and recyclable aluminium bottle. Explore our range here.

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