Alcoa, Ball, and Unilever partner to launch world’s first zero-carbon smelted aerosol can

USA – Alcoa, Ball Corporation, and Unilever have rolled out the initial consumer packaging made with ELYSIS carbon-free aluminium smelting technology. 

This aerosol can for personal and home care products contains 50% ELYSIS primary aluminium alongside 50% post-consumer recycled material. 

The partners view it as one of the lowest-carbon choices in the market today.

ELYSIS stems from a joint venture between Alcoa and Rio Tinto, with support from Apple and the governments of Canada and Québec. 

The technology swaps out traditional carbon anodes for inert ones during smelting, producing oxygen rather than carbon dioxide and wiping out direct greenhouse gas emissions at that stage. 

Deployment of the first full-scale plant is set to move forward this year.

Renato Bacchi, Alcoa’s executive vice-president and chief commercial officer, said the collaboration pushes low-carbon aluminium into routine items. 

He added that working together across the supply chain cuts carbon footprints in daily use.

The rollout comes just before the 30th United Nations Climate Change Conference, set for November 10 to 21 in Belém, Brazil. It highlights joint efforts to address growing needs for eco-friendly goods.

Ball Corporation’s chief sustainability officer and vice-president, Ramon Arratia, noted that blending high recycled content with low-carbon primary metal advances decarbonization across aluminium packaging. 

He called it a clear case of supply chain teamwork in action.

Alcoa handles production of bauxite, alumina, and aluminium, while Ball focuses on metal packaging solutions. Unilever brings its consumer goods reach to the table. 

This step fits into broader industry shifts, as seen in the November 2025 commitment by Nestlé, PepsiCo, Unilever, and TOMRA to the Ellen MacArthur Foundation’s 2030 Plastics Agenda for Business. 

That plan aims to accelerate progress in the circular economy for plastics and reduce global packaging waste.

The agenda supports calls from industry groups for more burdensome regulations after UN discussions on a worldwide plastic pollution treaty. 

With aerosol cans often relying on aluminium and propellants, this ELYSIS application extends beyond plastics to metal-based options, offering brands a path to lower emissions without major redesigns.

Industry watchers point to this as a practical move in the Middle East and Africa, where aluminium demand rises with consumer goods growth. 

Recent data shows regional packaging firms testing similar recycled blends, though full ELYSIS adoption awaits broader scaling. 

The can’s makeup could reduce lifecycle emissions by up to 80% compared to standard versions, according to partner estimates.

Unilever plans to expand the use of such materials across its lines, starting with trial runs in key markets. 

Ball aims to expand production capacity for these hybrid cans by mid-2026, targeting a 20% reduction in the average carbon intensity of its aerosol output.

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