Alcoa, Ball, partners Unilever 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 aluminum smelting technology. 

This aerosol can for personal and home care products contains 50% ELYSIS primary aluminum 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 moves forward this year.

Renato Bacchi, Alcoa’s executive vice-president and chief commercial officer, said the collaboration pushes low-carbon aluminum 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 levels with low-carbon primary metal advances decarbonization in aluminum packaging overall. 

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

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

This step fits into wider 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 targets faster circular economy progress for plastics and reduced global packaging waste.

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

With aerosol cans often relying on aluminum 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 aluminum 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 trim lifecycle emissions by up to 80% compared to standard versions, based on partner estimates.

Unilever plans wider 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% drop in average carbon intensity for its aerosol output.

Subscribe to our email newsletters that provide busy executives like you with the latest news insights and trends from Africa and the World. SUBSCRIBE HERE