Research highlights lack of consistent results from current can making technology

New global research from test and measurement partner, Industrial Physics, has exposed a critical issue in the metal packaging industry. The survey uncovered that the vast majority (92%) of professionals are unable to guarantee consistent, measurable results with current technology – highlighting a significant problem as the sector responds to sustainability and regulatory change.

The independent study surveyed 200 can making and filling professionals across the UK, US, Germany and India to evaluate how prepared the sector is for the operational, quality and sustainability challenges expected by 2028. The findings reveal an industry that understands what needs to change but remains constrained by outdated assumptions and hesitation to invest in modern measurement systems.

Quality risk emerged as one of the most pressing concerns. 86% of respondents said quality issues detected too late in production represent the greatest technical threat facing metal beverage cans. With modern lines running at speeds exceeding 2,000 cans per minute, even short delays in detection can result in tens of thousands of potentially defective units before corrective action is taken.

Commenting on the findings, Stefan Welker, strategic segment manager at Industrial Physics, shared: “The scale of the risk is difficult to overstate here. The impact of inaccurate, unreliable measurement is enormous and prohibits effective scaling and standardization between sites. Yet, the research confirmed our belief that misconceptions are holding manufacturers back. Action is critical, now is the time to investigate what is available and lean on a testing partner to solve knowledge gaps.”

The research highlighted a critical perception issue around testing technology. While 86% of respondents believe faster inspection compromises accuracy, the report challenges this assumption, pointing to modern inline measurement systems that deliver both speed and precision – a capability many manufacturers have yet to adopt.

Respondents also identified structural integrity (33%), cost control (31%) and sustainability targets (30%) as their top priorities for the next three years, exposing the intense pressure manufacturers face as they attempt to lightweight packaging, increase recycled aluminium content and maintain performance at the same time. The report describes this as a growing technical paradox: competing demands are converging faster than production systems are evolving, leaving many operations without the process control needed to manage risk effectively.

Regional confidence levels also varied sharply. While 96% of respondents in India expressed confidence in supply chain resilience approaching 2028, this fell to 92% in Germany, 84% in the US, and just 78% in the UK – highlighting how global trade dynamics and regulatory pressures are affecting markets differently.

Welker added: “The industry clearly understands what’s coming: tighter sustainability targets, increasing production complexity and zero tolerance for defects. What’s holding progress back isn’t technology – the solutions already exist. The onus is now on manufacturers to put awareness into measurable action. 

“Too many are still operating on outdated assumptions about what measurement technology can do. Those who invest now will be far better positioned to reduce waste, protect quality and meet regulatory expectations. Those who don’t are gambling with their brand, their output – and their future.”

The full report, Ready but not prepared: Metal Packaging’s 2028 reality check, explores how sustainability pressures, production complexity and quality expectations are converging, and what manufacturers must do now to remain competitive in the run-up to 2030 regulatory deadlines.

Download the report here: industrialphysics.com/campaign/ready-but-not-prepared-metal-packagings-2028-reality-check