Greener production
Aerosol cans on a production line. Image: Metaprint
Evert van de Weg examines the European aerosol can market, and the advantages of packaging aerosols in steel cans, along with Metaprint’s Martti Lemendik
Predicted growth for global aerosol cans could see the market going from 19 billion units in 2024 to 22 billion units in 2029 – moving at a CAGR of around three per cent. In Europe, the UK, Germany and France account for more than 55 per cent of the annual production in all market segments. Italy, Netherlands and Spain account for roughly another 25 per cent of the European actual total of 5.4 billion of aerosol cans.
The attractive properties of aerosol cans such as being leak-proof, user-friendly and recyclable, will keep driving the growth of the market. The popular and ever-expanding cosmetics and personal care industries will also act as significant factors behind the growth.
Metaprint & Protact steel cans
One important player in aerosols today is Metaprint, which was established in the Estonian city of Paldiski in 1891. In 1923, Metaprint began printing on metal sheet and in 2003, the company began the production of aerosol cans in its plant in the Estonian capital of Tallinn, where the head office of Metaprint is now based.
From then, developments happened in quick succession: in 2006, Metaprint introduced a new technology for the production of tops and bottoms of aerosol cans; in 2008, Metaprint started using UV offset printing; and in 2010, a new factory with technology for faster aerosol can production was opened in Tallinn.
More leaps forward followed: in 2013, two new aerosol can plants were opened, one in Pärnu, Estonia, to produce aerosol cans for food packaging, and one in Saint Petersburg, Russia. In 2016, the company introduced digital printing technology and in 2017 the company expanded the production of aerosol cans to a new plant in Heerenveen, the Netherlands. Today, Metaprint has more than 400 employees working in different production units in Estonia and the Netherlands. The company reports a sustainable growth based on standardised production processes and a steady staff with extensive experience in using the latest technologies and materials.
Metaprint’s Protact steel
aerosol can on display at the
2024 ADF Paris show. Image:
Antoine Duhamel Photography
During the recent ADF Paris show, Metaprint presented its new product, namely a three-piece aerosol can made from polymer coated Protact steel, produced by Tata Steel in Ijmuiden, the Netherlands. We spoke to the company’s CEO, Martti Lemendik, about the advantages of this new product offering. He commented, “The value offer of Protact steel is to expand the usage of steel aerosol containers, which offer better protection for a wider range of product formulations. Tata Steel Nederland can also provide it in a combination of low-carbon emission Zeremis steel as a substrate material. This means we can combine several advantageous qualities – with the base material being low carbon footprint steel and its surface being protected by a superior polymer coating.”
Lemendik said that this, in many ways, can be called a “super can.” He also added that “when applying the polymer coating, our mechanical process does not generate the VOC emissions that standard can coating does.
“Cans made from Protact steel are offering extra value to users in several different ways – reduced/ no leakage issues for fillable formulations where standard complex internal coating systems failed; excellent visual appearance via high quality print on it, availability via short lead-times – if you order it from Metaprint, it means 14 days lead-time.”
In terms of when Protact will be introduced to Metaprint customers, Lemendik said that “several customers have started the pack tests already, and we expect the first user cases available during 2024.”
Market projections & opportunities
Lemendik told CanTech International that the aerosol can market will remain challenging in 2024. He said, “On one hand, we do not expect further reduction in demand, but the industry is facing continuous erosion of margins. It has been a buyers’ market for the last couple of years and this has an impact on the market members behaviour. It does not mean that we completely miss the optimism, but we can’t report about huge growth figures. The output of our can making plant in Estonia will most probably remain on its current level. Growth is expected to come from our Dutch plant.
“Market awareness of low carbon footprint cans is rising, and we’re placed well with our offerings. We believe that cans made out of Bluemint steel (CO2 reduced and certified steel from thyssenkrupp) or Zeremis steel (low carbon emission steel from Tata Steel) are the right choice for fillers who are realising their responsibility toward environment and society. These ‘greener steel’ options offer a reduction of around two-thirds of CO2 emissions compared to standard ‘grey steel.’”
Lemendik said that, for the year ahead geographically, his “biggest concerns are related with the German market as its economy is not demonstrating historical robustness.” He explained: “It is one of the largest markets in Europe and this has an impact on the overall results of Metaprint. Regarding the rest of the European countries – there is a reason to be more optimistic. In case of positive change in the Russian-Ukrainian war, we could see a high surge in demand for aerosol products.”
Lightweighting also has an important part to play in market growth, Lemendik stated. “Metaprint is dedicated to bringing lighter cans to the market, where we reduce the environmental impact via downgauged material thicknesses without making compromises in can performance. Historical can body material thicknesses of 0.15mm or 0.16mm have been replaced by 0.13mm thickness thanks to technology such as new generation seamers,” he said. In terms of additional future Metaprint projects, Lemendik commented, “In the coming years, we expect to see the biggest developments in printing and coating technology. Both these processes contribute significantly to our carbon footprint, and it is our duty to reduce it. UV LED curable inks and coatings are close to breakthrough. Digital printing technology is capable of increasing production speed and cutting costs.
“For Metaprint, the year 2024 will see the introduction of second-generation digital printing technology that is based on almost ten years of pioneering in this field.
