The metal packaging industry is navigating a transformative era. Global markets demand enhanced sustainability, greater operational efficiency and strict adherence to regulatory frameworks. For years, solvent-based coatings have represented the industry benchmark – trusted, familiar, and deeply embedded in production infrastructure. But the ground is shifting. Rising energy costs. Tightening rules on air pollution. The old benchmark is cracking; the limitations of solvent-based coatings are getting harder to ignore.

The critical question becomes clear: How do you meet these pressures without sacrificing quality and performance? The answer lies in a shift already underway: the move to energy-cured UV solutions.

Why a Shift is Essential

To understand why change is inevitable, it helps to examine what solvent-based coatings are made of. Between 40-60% of the formulation consists of solvents – solvents either evaporate into the atmosphere as VOCs or require costly incineration to manage, adding to the carbon footprint at every stage of production.

The curing infrastructure these systems rely upon presents its own set of challenges. Large energy-intensive curing ovens needed for these coatings occupy valuable floor space and add greenhouse gases without improving performance. The result is a production environment under strain: slower throughput, higher operating costs, and process rigidity that sits at odds with the agility modern converters need to remain competitive.

“Energy-curable coatings are no longer a niche solution – they’re the inevitable next step,” says Emilie Vedel Blankschøn, Product Manager Energy Curing Coatings & Sustainability at ACTEGA, a leading inks, coatings, compounds and adhesives manufacturer for the metal packaging industry. “The real question isn’t if a transition away from solvent-based coatings will happen, but how quickly.”

The Power of 100% Solids UV Coatings

This is where ACTEGA’s ACTNext® coatings change the equation. Engineered for UV and UV LED coatings, ACTNext® combines sustainability with uncompromised performance, delivering the precision and speed modern manufacturing operations require without compromising production efficiency. Designed to meet stringent regulatory standards, ACTNext® offers versatility across a wide range of external coatings applications for drums, general line, closures, and selected food cans. With seamless integration into factory workflows, ACTNext® supports both high-speed inline and batch inspection processes.

The numbers tell the story:

• Speed: A thermal oven can take over 8 minutes to cure at more than 180°C. UV lamps do it in under a second.
• Savings: Energy costs cut by up to 30%.
• Sustainability: A lifecycle analysis with Brasilata, verified by Ramböll, showed a 40% emissions reduction across the value chain — and 95% at the can maker facilities.

The Breakthrough: The UV Direct to Metal

For decades, direct application of UV coatings to metal was considered impractical because of adhesion challenges. The breakthrough came with atmospheric plasma pre-treatment, developed in collaboration with Vislo (formerly Brasilata Labs) and Plasmatreat GmbH.

By cleaning and activating the metal surface, plasma creates the perfect foundation for ACTNext®. No conventional, solvent-based basecoats. No giant gas ovens. Just efficient UV lamps, faster line speeds, lower costs, and a far smaller equipment footprint.

“We’ve validated the technology in real industrial environments, not just in the lab. Running commercially for over three years, we’ve shown it works on an industrial scale,” Blankschøn adds.

Ready to Future-Proof Your Production?

Solvent-based solutions will continue to lose their share. Energy-curing coatings will set a new standard for can makers. The only real question is whether you lead or lag.

“At ACTEGA, we work hand-in-hand with our customers to ensure a smooth transition, providing the expertise, technology, and support to help metal packaging manufacturers future-proof their operations,” concludes Blankschøn.

Ready to see what ACTNext® can do for your operation? Visit actega.com to start the conversation. Let’s advance your operation together with ACTNext®.