Compressed air is used throughout aluminum can manufacturing to actuate cylinders, operate clutches and brakes, eject cans from machinery, and support forming operations. Vacuum systems also play an important role in holding cans in position during trimming, printing, coating, and flanging.
Because can manufacturing operates at high production speeds, compressed air demand can be substantial. Requirements also vary from one line to another depending on equipment size, can dimensions, production speed, and the number of machines operating together.
Step 1: Forming the Initial Cup
Aluminum cans begin as large rolls of flat aluminum sheet. A single roll can weigh up to nine tons and may produce as many as 750,000 cans.
The sheet is fed into a punch press, often called a cupper, which performs two operations: cutting a circular disk from the sheet and forming that disk into a shallow cup. Remaining aluminum is collected and returned for recycling.
Either oil-flooded or oil-free compressed air can be used to operate the clutch and brake systems and eject the formed cups from the machine.
Typical compressed air demand is 100 to 500 scfm at 95 to 100 psi, although actual requirements depend on cupper size and manufacturer specifications.
Steps 2 and 3: Drawing, Ironing, and Trimming the Can Body
The formed cup next enters the draw-and-iron process, where the aluminum is stretched and shaped into the familiar cylindrical can body. The can is then trimmed to the required height.
Compressed air is used to eject cans and operate clutch, brake, and pneumatic cylinder functions. Vacuum is also used to hold the can securely on the chuck during trimming.
Typical requirements from the source application are:
Draw-and-iron compressed air: approximately 50 scfm at 95 to 100 psi
Vacuum demand: approximately 15 scfm
Step 4: Washing the Cans
After forming and trimming, the cans travel upside down along the conveyor to a washer, where they pass through a six-stage cleaning process.
Compressed air is used to operate valve actuators within the washer. Either oil-flooded or oil-free compressed air may be used depending on the equipment and process requirements.
Typical demand is 45 to 50 scfm at approximately 100 psi.
Step 5: Printing the Exterior
Once cleaned, the exterior of the cans is printed. Some production lines can process up to 1,800 cans per minute.
Oil-free compressed air is used to operate the clutch, brake, and pneumatic cylinders. Vacuum holds each can on the chuck during printing.
Typical demand is:
Compressed air: approximately 35 scfm at 95 to 100 psi
Vacuum: approximately 120 scfm
Step 6: Applying the Internal Coating
The inside of each can is coated to create a barrier between the aluminum and the beverage it will eventually contain.
Compressed air operates the pneumatic cylinders used in this stage, while vacuum holds the can in position during application of the internal coating.
Typical demand is:
Compressed air: approximately 50 scfm at 95 to 100 psi
Vacuum: approximately 145 scfm
Step 7: Necking and Flanging
The can then moves through a die-necker, which gradually reduces the diameter at the top of the can through multiple forming stages.
Oil-free compressed air supports the can during the die process and operates clutch, brake, and pneumatic cylinder functions.
Compressed air demand can range from 500 to 2,500 scfm, depending on the number of machine banks connected to the system.
Vacuum is also used to hold the can during the flanging process, with typical demand of approximately 5 to 10 scfm.
Final Inspection and Packaging
After forming is complete, the cans pass through a vision inspection system that checks the interior of each container. Cans that do not meet the required criteria are removed and sent for recycling.
Accepted cans are packed and palletized before being shipped to beverage producers for filling and final closure.
Compressed Air Demand Varies by Canning Line
No two aluminum can manufacturing systems have exactly the same compressed air requirements. The number of production lines, can dimensions, machine configuration, and production speed all influence system demand.
That variation makes it important to evaluate the complete air and vacuum load rather than relying on a single rule-of-thumb value. Understanding where compressed air is used, how much each machine consumes, and whether the application requires oil-free air can help ensure the system is sized appropriately for the production line.
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Compressed air is used throughout aluminum can manufacturing to actuate cylinders, operate clutches and brakes, eject cans from machinery, and support forming operations. Vacuum systems also play an important role in holding cans in position during trimming, printing, coating, and flanging.
Because can manufacturing operates at high production speeds, compressed air demand can be substantial. Requirements also vary from one line to another depending on equipment size, can dimensions, production speed, and the number of machines operating together.
Step 1: Forming the Initial Cup
Aluminum cans begin as large rolls of flat aluminum sheet. A single roll can weigh up to nine tons and may produce as many as 750,000 cans.
The sheet is fed into a punch press, often called a cupper, which performs two operations: cutting a circular disk from the sheet and forming that disk into a shallow cup. Remaining aluminum is collected and returned for recycling.
Either oil-flooded or oil-free compressed air can be used to operate the clutch and brake systems and eject the formed cups from the machine.
Typical compressed air demand is 100 to 500 scfm at 95 to 100 psi, although actual requirements depend on cupper size and manufacturer specifications.
Steps 2 and 3: Drawing, Ironing, and Trimming the Can Body
The formed cup next enters the draw-and-iron process, where the aluminum is stretched and shaped into the familiar cylindrical can body. The can is then trimmed to the required height.
Compressed air is used to eject cans and operate clutch, brake, and pneumatic cylinder functions. Vacuum is also used to hold the can securely on the chuck during trimming.
Typical requirements from the source application are:
Step 4: Washing the Cans
After forming and trimming, the cans travel upside down along the conveyor to a washer, where they pass through a six-stage cleaning process.
Compressed air is used to operate valve actuators within the washer. Either oil-flooded or oil-free compressed air may be used depending on the equipment and process requirements.
Typical demand is 45 to 50 scfm at approximately 100 psi.
Step 5: Printing the Exterior
Once cleaned, the exterior of the cans is printed. Some production lines can process up to 1,800 cans per minute.
Oil-free compressed air is used to operate the clutch, brake, and pneumatic cylinders. Vacuum holds each can on the chuck during printing.
Typical demand is:
Step 6: Applying the Internal Coating
The inside of each can is coated to create a barrier between the aluminum and the beverage it will eventually contain.
Compressed air operates the pneumatic cylinders used in this stage, while vacuum holds the can in position during application of the internal coating.
Typical demand is:
Step 7: Necking and Flanging
The can then moves through a die-necker, which gradually reduces the diameter at the top of the can through multiple forming stages.
Oil-free compressed air supports the can during the die process and operates clutch, brake, and pneumatic cylinder functions.
Compressed air demand can range from 500 to 2,500 scfm, depending on the number of machine banks connected to the system.
Vacuum is also used to hold the can during the flanging process, with typical demand of approximately 5 to 10 scfm.
Final Inspection and Packaging
After forming is complete, the cans pass through a vision inspection system that checks the interior of each container. Cans that do not meet the required criteria are removed and sent for recycling.
Accepted cans are packed and palletized before being shipped to beverage producers for filling and final closure.
Compressed Air Demand Varies by Canning Line
No two aluminum can manufacturing systems have exactly the same compressed air requirements. The number of production lines, can dimensions, machine configuration, and production speed all influence system demand.
That variation makes it important to evaluate the complete air and vacuum load rather than relying on a single rule-of-thumb value. Understanding where compressed air is used, how much each machine consumes, and whether the application requires oil-free air can help ensure the system is sized appropriately for the production line.
AIR TECHNOLOGY & SERVICES