Germany’s sole tinplate manufacturer, thyssenkrupp Rasselstein, has unveiled a suite of technical innovations aimed at high-efficiency production and material reduction.

The developments focus on high-performance steel grades and digital calculation tools that allow manufacturers to down-gauge without losing structural integrity.

Advanced Steel Grades for aerosols and food cans

The company has expanded its specialised portfolio with two key grades designed for specific high-stress applications:

• rasselstein D&I Solid: Developed for two-piece food cans, this next-generation Draw and Ironing (D&I) material is engineered to enable material savings of up to 10%. The grade allows for significant thickness reductions while maintaining the stability required for modern canning lines.
• rasselstein CUP: Targeted at aerosol can mounting cups, this “Ultimate Performance” steel combines high formability with increased strength and low earing, ensuring the mounting cup remains stable under the internal pressures of aerosol delivery.

The “Canculator”: digital down-gauging

To assist manufacturers in optimising their material usage, Rasselstein has introduced the Canculator. This digital tool, integrated into the company’s Packaging Steel App, uses Finite Element Analysis (FEA) and machine learning models to estimate achievable thickness reductions.

The interface allows users to adjust production parameters and receive customer-specific calculations in seconds. By bridging the gap between metallurgy and digital modeling, the tool provides data-driven insights into how the D&I Solid grade can be thinned without compromising the safety or performance of the container.

Decarbonisation efforts

Beyond physical and digital efficiency, the company continues to push its bluemint Steel line. This $CO_2$-reduced tinplate is a primary component of Rasselstein’s strategy to support the packaging industry’s transition toward a circular economy and lower Scope 3 emissions.

According to Clarissa Odewald, CEO of thyssenkrupp Rasselstein GmbH, these solutions are a direct response to the current challenges of resource scarcity and the demand for increased efficiency across the global supply chain.