The metal packaging industry is navigating a transformative era. Global markets demand enhanced sustainability, greater operational efficiency including energy savings, and strict adherence to regulatory frameworks, both converters and brand owners face considerable pressure to adapt. For years, solvent-based coatings have represented the industry benchmark – trusted, familiar, and deeply embedded in production infrastructure. However, with escalating energy costs, evolving environmental legislation on air pollution limits, and spatial constraints, the industry standards are showing their cracks, and solvent-based coatings are now revealing their limitations. 

The critical question for industry professionals is evident: How can the industry address these production challenges while upholding product quality and performance benchmarks? The strategic response lies in the evolution of coating formulations, particularly the transition towards energy-cured UV solutions.  

A new era for coating technologies – Why a shift is essential

Innovation in the metal packaging sector is advancing rapidly, driven by the need for future-proofing operations, where efficiency, sustainability, and innovation are the new currency. Advanced coating solutions are now at the forefront, ensuring the quality and performance of metal packaging. By addressing challenges such as eliminating VOC emissions and lowering energy consumption, these technologies not only maintain quality standards but also redefine the possibilities in production. 

Solvent-based coatings, traditionally regarded as industry workhorses, are facing increasing scrutiny due to operational and environmental limitations, which can impact the entire production chain. The core of the issue lies in their composition, where 40-60% of the formulation consists of solvents. These solvents either evaporate into the atmosphere as VOCs or require costly incineration, adding to the carbon footprint. Furthermore, the large energy-intensive curing ovens needed for these coatings occupy valuable floor space and add greenhouse gases without improving performance. This dependency on thermal curing not only increases operational costs but also restricts production speed and manufacturing flexibility.

Emilie Vedel Blankschøn, Product Manager Energy Curing Coatings & Sustainability at ACTEGA, a leading inks, coatings, compounds and adhesives manufacturer for the metal packaging industry, comments: “The industry is at a critical juncture, grappling with both environmental and economic pressures. Modern production demands leaner operations. In this landscape, energy-curable coatings are no longer a niche solution – they’re the inevitable next step. The real question isn’t if a transition away from solvent-based coatings will happen, but how quickly.”

100% Solids UV coatings: A technological advancement

This is precisely where ACTEGA’s ACTNext coatings emerge as a powerful solution. Engineered for UV and UV LED coatings, ACTNext combines sustainability with uncompromised performance, delivering the precision, speed, and sustainability required for modern manufacturing operations 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.

Leveraging advanced formulations that cure almost instantly under UV light, these 100% solids systems eliminate the need for solvent evaporation. Unlike thermal ovens that can take over 8 minutes to cure a coating at >180 °C, UV lamps achieve this in less than a second. This instant curing accelerates production cycles, enabling higher throughput and reducing energy costs by up to 30 percent. A comparative lifecycle analysis conducted with Brasilata and verified by Ramböll demonstrates that switching from a solvent-based to a UV-based overprint coating can lower emissions by 40% across the value chain and by 95% at the canmaker facilities. This improves throughput, while ensuring superior durability and finish. With seamless integration into factory workflows, ACTNext supports both high-speed inline and batch inspection processes, adapting to diverse production requirements. 

The game-changer: The UV direct to metal revolution

One of the most notable developments within the ACTNext portfolio is UV Direct to Metal for general-line cans, a technology born from a groundbreaking collaboration with Vislo (former Brasilata Labs) and Plasmatreat GmbH. For decades, the direct application of UV coatings to metal was considered impractical due to challenges with adhesion. The breakthrough came with atmospheric plasma pre-treatment, which cleans and activates the metal surface, creating the perfect foundation for the ACTNext UV coatings.

This patented process is a paradigm shift. By preparing metal surfaces with atmospheric plasma, the need for conventional, often solvent-based, basecoats is eliminated. Instead of curing in large gas ovens, the process uses highly efficient UV mercury lamps, dramatically reducing energy consumption and freeing up valuable floor space.

In trials at Brasilata’s plant in São Paulo, the technology delivered not only the expected environmental benefits but also significant operational gains, including faster line speeds, lower overall costs, and a much smaller equipment footprint. “We’ve validated the technology in real industrial environments, not just in the lab. Having been running commercially for over three years, we’ve shown it works on an industrial scale,“ adds Emilie Vedel Blankschøn.

Looking forward: A future defined by energy-curing coatings

As industry evolves, solvent-based solutions will continue to lose its share, and energy-curing coatings will set the new standard for can makers. The question is no longer whether they should adapt, but whether they will lead or lag. 

“Energy-curing coatings will shape the future of metal packaging. Of course, meaningful change doesn’t happen overnight. The transition presents its own set of challenges for converters, like investment timing and infrastructure adjustments. At ACTEGA, we understand these realities. 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 Emilie Vedel Blankschøn. 

Ready to future-proof your production? 

The shift to energy-curing coatings is no longer a question of if, but when.  The ACTNext portfolio offers more than just coatings – it offers a tangible competitive advantage built on sustainability, efficiency, and innovation. 

Ready to see what ACTNext can do for your operation? Contact ACTEGA (Emilie.VedelBlankschoen@altana.com) today to discuss your specific applications. Our teams are here to support you with comprehensive trials, seamless onboarding, and ongoing technical guidance.

Visit actega.com to learn more. Let’s advance your operation together with ACTNext.