Rexam CRM

BEVERAGE CAN
Europe and Asia
Customer Reference Manual
© Rexam Beverage Can Europe Limited. 2004. All Rights Reserved

BEVERAGE CAN
Europe and Asia
Contents Introduction 1
2 Contacts & Locations
Can and End Making Process 3
4 Can Product Data Sheets
End Product Data Sheets 5
6 Manufacturing Codes and Traceability
Artwork Guidelines 7
8 Pallet Specifications for Cans and Ends
Labels for Can and End Pallets 9
10 Quality Criteria
Product Formulation and Test Packs 11
12 Can Handling / Pasteurisation
Seam Specifications 13
14 Special Packaging Techniques
Training Courses 15
16 Appendix
The information and guidance provided in this manual is general and may not apply to specific situations. Rexam does not warrant the accuracy
of the information contained in the Manual and specific advice should be taken before taking any action based on the information provided.
Rexam accepts no responsibility for any liability loss or damage incurred by any person, firm or company arising as a result of reliance on the
information or guidance contained in the Manual.
BEVERAGE CAN
Europe and Asia
INTRODUCTION
Introduction to Rexam .... > Innovation .... >
Our Vision .... > Investment in People .... >
Service .... > The Environmental Approach .... >
Quality .... >
Section 1 – Page 1 Back to index < >

BEVERAGE CAN
Europe and Asia
INTRODUCTION
Rexam (www.rexam.com) is one of the world's top five consumer packaging groups. We are a leading global
beverage can maker and the No 1 can maker in Europe. Our global operations focus on beverage packaging in metal,
glass and plastic, and plastic packaging solutions for the beauty, healthcare, and food industries around the world.
The Rexam Group employs some 22,000 people in around 20 countries worldwide and has an ongoing turnover of
approaching £3.4 billion.
REXAM BEVERAGE CAN EUROPE & ASIA

Rexam’s can business supplies more than 45 billion aluminium and steel cans to soft drink and beer industries
worldwide. This makes Rexam one of the world’s leading can makers and the No 1 can maker in Europe.
Our European can sector, Rexam Beverage Can Europe & Asia, has 15 can and 4 end plants strategically located
across Europe to provide our customers with the highest levels of service. We also have partnerships in Korea, Egypt
and China. We have the capability of producing 13 different can sizes from 15cl to 56.8cl and a range of innovative
technologies that can be used to enhance product profile and brand image. Our highly automated plants operate at line
speeds of up to 2000 cans per minute and in any one year we have the capacity to produce over 19 billion cans and
ends. Our sector head office is in Luton in the UK. In total our sector employs 3,300 people.

BEVERAGE CAN
Europe and Asia
OUR VISION
At Rexam our vision is to be the leading consumer packaging group in each of our chosen market segments.
Leading means not necessarily in size, but in service, quality, innovation and efficiency. Leading also involves creating a
stimulating and rewarding environment for all our employees.

BEVERAGE CAN
Europe and Asia
SERVICE – UNDERSTANDING AND EXCEEDING A CUSTOMER’S EVERY NEED

In an increasingly demanding global business, the level of service that we provide is critical both to our customers and
to our own long-term success. Excellence in service is therefore a key priority for us. One of the most important elements
of service at Rexam Beverage Can Europe & Asia is the close working relationship that we share with our customers.
We adopt an open, team-based approach throughout all areas of business.
To provide flexible service to customers, irrespective of their location, we can switch orders between plants while
maintaining quality standards. The use of single hauliers in many key markets ensures the same high level of quality and
service wherever our customers are based.
Our technical customer support staff are always available to assist our customers, whether it be to provide advice during
procurement and installation of filling equipment, or in training personnel in filling, seaming and can handling. In
graphics we continue to lead the industry in providing improved efficiencies and quicker response times.

BEVERAGE CAN
Europe and Asia
QUALITY – AT THE HEART OF EVERYTHING WE DO

Product quality is as critical for us, as it is for our customers. All of our Western European plants are ISO 9002
accredited and follow strict European quality procedures which are constantly updated and improved upon.
Our focus on quality and efficiency does not finish once our products leave the plant, but continues right though our
customers operations and on to the consumer.
One of the key drivers for quality is Six Sigma, an initiative which is part of our continuous improvement programme
and which is helping us improve our quality year on year.
Six Sigma is a process-focussed method that provides an overall framework for quality. The approach encompasses
problem-solving techniques and puts particular emphasis on measuring, analysing, improving and controlling industry
processes. Put simply, Six Sigma means finding the cause of a problem, putting it right and maintaining this
improvement.
By putting quality at the very heart of what we do, we are able to ensure that we remain the most reliable and highest
quality supplier in our industry.
All of our plants are ISO 9002 accredited.

BEVERAGE CAN
Europe and Asia
INNOVATION – IN WHAT WE PRODUCE AND THE WAY WE WORK

At Rexam Beverage Can Europe & Asia, we believe in bringing innovation not only to what we make, but also to the
way in which we make our products and work with our customers, continuously embracing new technologies and
business approaches.
As our customers demand for diversity grows, so we continue to develop new kinds of product. Providing our customers
with an ever-increasing range of innovative quality products is the task of our marketing, engineering and development
teams, consisting of some of the most experienced people from around the world. We currently offer 13 different can sizes
to suit a wide variety of products and drinking occasions.
We’re opening up new marketing opportunities by pioneering techniques in embossing, fluting, shaping, inks and coatings
and also offer a variety of promotional ends and tabs. By working closely with our customers, we are able to develop new
methods of adding value to their business and in doing so provide them a competitive edge in the marketplace.

BEVERAGE CAN
Europe and Asia
INVESTMENT IN PEOPLE – AT THE CENTRE OF REXAM’S BUSINESS PHILOSOPHY

In order to achieve our vision of leadership in service, quality, innovation and efficiency, we need to constantly attract,
retain and motivate the very best people.
This involves fostering the right corporate culture based on teamwork, trust, recognition and continuous improvement.
It also demands that we provide people with the right opportunities for personal development and growth.
At Rexam we have developed a number of training and development programmes that help our people realise their
individual ambitions and potential, so that together, we are able to fulfil the collective goals of our business.

BEVERAGE CAN
Europe and Asia
THE ENVIRONMENTAL APPROACH THAT MAKES GOOD BUSINESS SENSE

Sound environmental policies are crucial to the sustainable future growth of our business. Customers and consumers
want packaging that achieves more, but uses less raw material.
At Rexam we are committed to optimising the use of resources to balance consumers packaging expectations with the
environmental impact that it causes. Environmental management involves taking a complete overview, from the supply of
raw material to the disposal of products after they have been used.
We actively work with local manufacturers and retailers in developing optimum packaging and packaging recovery
solutions for local conditions. The excellent recycling performance of steel and aluminium cans provides a good starting
point: the can is the most recycled beverage container in the world.
The aim is for a harmonised framework of products and policies wherever Rexam operates. This culture is reinforced
through in-house training and is supported by top level management.
All of our plants are ISO 14001 accredited.

BEVERAGE CAN
Europe and Asia
CONTACTS & LOCATIONS
Where we are .... >
Who we are .... >
Who to contact .... >

BEVERAGE CAN
Europe and Asia
EUROPE’S No1
Wakefield Fosie Recklinghausen
United Kingdom : Cans Sweden : Cans Germany : Cans & Ends
15 can plants and 4 end
plants across Europe.
Capacity in excess of 19
billion can per annum Waterford
Ireland : Ends
Berlin
Germany : Cans
1
Head Office Milton Keynes

United kingdom
United kingdom : Cans
2 Naro-Fominsk
Russia : Cans & Ends
1 3
2
Tongwell Dunkerque
France : Cans Gelsenkirchen
United kingdom Germany : Cans
Oss Mont Ejpovice

France : Ends Czech Republic : Cans
The Netherlands
Valdemorillo La Selva Nogara San Martino Manisa Enzesfeld

Spain : Cans Spain : Cans Italy : Cans Italy : Cans Turkey : Cans Austria : Cans

BEVERAGE CAN
Europe and Asia
LOCATION ADDRESSES
Rexam Beverage Can Europe Limited Rexam Beverage Can Enzesfeld GmbH
100 Capability Green Hauptstrasse 11
Luton, UK AT-2551 Enzefeld
LU1 3LG Austria
Tel: +44 (0)1582 408999 Tel: +43 (0)2256 8080
Fax: +44 (0)1582 408806 Fax: +43 (0)2256 816292
Rexam Beverage Can Europe Limited Rexam Beverage Can Ejpovice, Czech Republic
Delaware Drive, CZ-3302 Dysina
Tongwell Czech Republic
Milton Keynes, UK Tel: +420 19 78305
MK15 8HG Fax: +420 19 78305
Tel: +44 (0)1908 517600
Fax: +44 1908 517601
Rexam Beverage Can France SAS
Route de Vignots
Rexam Beverage Can Europe Limited Z.I.P.des Huttes
Holland 59820 Gravelines
Ijsselstraat 30 France
5347 KG Tel: +33 (0)328 235100
Oss, Holland Fax: +33 (0)328 265110
Tel: +31 (0)412 660800
Fax: +31 (0)412 645030

BEVERAGE CAN
Europe and Asia
Rexam Beverage Can France SAS Rexam Beverage Can Gelsenkirchen GmbH
Usine de Mont Emscherstrasse 46
B.P.17 4589 Gelsenkirchen
64300 Mont Germany
France Tel: +49 (0)2097 0020
Tel: +33 (0)559 387777 Fax: +49 (0)2097 5699
Fax: +33 (0)559 676842
Rexam Beverage Can Ireland Limited
Waterford Industrial Estate
Rexam Beverage Can Berlin GmbH Cork Road
Postfach 370429 Waterford
DE-14134 Berlin Ireland
Germany Tel: +353 (0)513 72137
Tel: +49 (0)30 847830 Fax: +353 (0)513 78892
Fax: +49 (0)30 817 5087
Rexam Beverage Can Italia Srl

Rexam Beverage Can Recklinghausen Gmbh Localita Compotrino 48
Postfach 200320 Zona Industriale
DE-45633 Recklinghausen 66010 San Martino Sulla
Germany Marrucina
Tel: +49 (0)2361 6030 Chieti
Fax: +49 (0)2361 603270 Italy
Tel: +39 0871 84641
Fax: +39 0871 84644

BEVERAGE CAN
Europe and Asia
Rexam Beverage Can Italia Srl Rexam Beverage Can Iberica SL

Via Molino di Sopra 64 Poligono Industrial Silva
37054 Nogara (VR) 43470 La Selva del Camp
Italy Tarragona
Tel: +39 (0)442 537555 Spain
Fax: +39 (0)442 539107 Tel: +349 (0)777 58700
Fax: +349 (0)777 58736
Rexam Beverage Can Naro-Fominsk

1 Zavodskaya Street Rexam Beverage Can Fosie AB
Naro Fominsk Box 9016
Russia 143300 SE-200 39 Malmo
Tel: +7 095 797 4455 Sweden
Fax: +7 095 797 4460 Tel: +46 (0)40 209300
Fax: +46 (0)40 209420
Rexam Beverage Can Iberica SL

Ctra.M-600 Km20 Rexam Paketleme Sanayi ve Ticaret AS
Valdemorillo 28210 Organize Sanayi Bolgesi
Spain 50.Y.I Cad 45030
Tel: +349 (0)189 73200 Manisa
Fax: +349 (0)189 73256 Turkey
Tel: +90 (0)236 233 0420
Fax: +90 (0)236 233 1275

BEVERAGE CAN
Europe and Asia
Rexam Beverage Can Europe Limited

Northfields Drive
Northfields
Milton Keynes, UK
MK15 0DA
Tel: +44 (0)1908 240505
Fax: +44 (0)1908 607447
Rexam Beverage Can Europe Limited

Kenmore Road
41 Industrial Park
Wakefield, UK
WF2 OXE
Tel: +44 (0)1924 829561
Fax: +44 (0)1924 825536

BEVERAGE CAN
Europe and Asia
CTS CONTACTS
COUNTRY CONTACT MOBILE NO. EMAIL
Austria/Czech Republic Werner Koch (+43) 6646 116511 werner.koch@rexam.com
Jurgen Maier (+43) 6646 116513 jurgen.maier@rexam.com
The Benelux Camille van der Helm (+31) 622 208033 camille.vanderhelm@rexam.com
France Christophe Casail (+33) 680 891622 christophe.casail@rexam.com
Germany Uwe Schmolling (+49) 1728 468946 uwe.schmolling@rexam.com

Gerd Hontzsch (+49) 1723 177684 gerd.hontzsch@rexam.com
Rainer Doernemann (+49) 1735 255155 rainer.doernemann@rexam.com
Rolf Gockel (+49) 1722 020181 rolf.gockel@rexam.com
Josef Stamer (+49) 1735 363937 josef.stamer@rexam.com
Rainer Gebhard (+49) 1716 916183 rainer.gebhard@rexam.com
Karl Korfer (+49) 1717 856205 karl.korfer@rexam.com
Italy Ricardo Bottura (+39) 348 5146375 ricardo.bottura@rexam.com

Claudio Scarmagnani (+39) 348 9490877 claudio.scarmagnani@rexam.com
Marco de Ritis (+39) 348 9490977 marco.deritis@rexam.com

BEVERAGE CAN
Europe and Asia
COUNTRY CONTACT MOBILE NO. EMAIL

Nordic Countries Christer Sjostrom (+46) 709 269493 christer.sjostrom@rexam.com
Dzaladin Salih (+46) 708 909412 dzaladin.salih@rexam.com
Ronnie Malmborg (+46) 702 073689 ronnie.malmborg@rexam.com
Nicklas Andersson (+46) 708 299479 nicklas.andersson@rexam.com
Russia Victor Diakov (+7) 095 769 2519 victor.diakov@rexam.com

Victor Tretiakov (+7) 095 769 2521 victor.tretiakov@rexam.com
Spain Joaquin Mingo (+34) 629 792939 joaquin.mingo@rexam.com

Javier Sainz (+34) 639 138107 javier.sainz@rexam.com
Manuel Garvi (+34) 639 135479 manuel.garvi@rexam.com
Juan-Carlos Perez (+34) 639 138115 juan-carlos.perez@rexam.com
Turkey Oguzhan Dirik (+90) 532 214 2731 oguzhan.dirik@rexam.com
UK Graham Fenton (+44) 7774 825292 graham.fenton@rexam.com

Tom Telfer (+44) 7831 195368 tom.telfer@rexam.com
Tony Crofts (+44) 7774 826571 tony.crofts@rexam.com
Phil Gage (+44) 7774 826569 phil.gage@rexam.com
Kevin Lee (+44) 7721 894354 kevin.lee@rexam.com
David Pearce (+44) 7721 483117 david.pearce@rexam.com
Jeff Waine (+44) 7774 826572 jeff.waine@rexam.com

BEVERAGE CAN
Europe and Asia
CAN AND END MAKING PROCESS
The Can Making Process .... >
The End Making Process .... >

BEVERAGE CAN
Europe and Asia
THE CAN MAKING PROCESS

A high precision process using advanced engineering and technology
STEP 1 CUPPER
Aluminium or sheet steel arrives at the can manufacturing plant in
huge coils. The sheet is fed continuously from an un–coiler into a
cupping press, which cuts out thousands of discs per minute and
forms them into shallow cups. This is called the blank and draw
process. Surplus material is recycled
STEP 2 BODYMAKER
The cups are transported to the bodymaker, where the can
begins to take its final shape. In the bodymaker, the cup is
placed in a front of a moving ram, which forces it through a
series of precision rings, each a little smaller than the previous
one. This reduces the thickness of the metal (Wall Ironing) and as
a result the can gets taller. At the end of the stroke the base is
formed and the can is removed from the ram.

BEVERAGE CAN
Europe and Asia

STEP 3 TRIMMER AND WASHER

The trimmer cuts the can to the correct height. The surplus
material from the process is recycled.
Trimmed cans pass through highly efficient washers to remove
lubricants used during the forming process and prepare the can
surface for coating and printing. Cans are then dried in an oven.
STEP 4 BASECOATER
Depending on customer and design requirements, cans may be
externally coated with a white or clear base coat.

BEVERAGE CAN
Europe and Asia

STEP 5 PRINTER
The next step is a highly sophisticated decorator which applies
the customers design to the cans using up to six colours. All six
colours are printed onto the can in the same operation. A clear
coat overvarnish is sometimes added to the printed cans to give
a glossy finish
STEP 6 INTERNAL LACQUER

The inside of each can is sprayed with a coating.
This special layer is to protect the product in the can from
interaction with the metal.

BEVERAGE CAN
Europe and Asia

STEP 7 NECKER AND FLANGER

The cans are passed through a necker/flanger which gives the
characteristic neck shape. Here the diameter of the top of the can
is flanged outwards to enable the end to be seamed on after the
cans are filled
STEP 8 QUALITY CONTROL

Cans are quality tested at each stage of manufacture. At the final
stage, the can is put through a series of additional tests including
a light tester and internal and external inspection cameras. Any
defective cans are automatically rejected.

BEVERAGE CAN
Europe and Asia
STEP 9 PALLET PACKER

Finally the cans are packed on to pallets which are then either
sent to our warehouse for storage or transported directly to the
brewery or soft drink producer for filling.
Recovery and recycling of beverage cans in europe has increased steadily during recent years and it is now the most recycled drinks
container in the world.

BEVERAGE CAN
Europe and Asia
THE END MAKING PROCESS

The beverage can end is a highly sophisticated product that Conversion: The final part of the process is converting the
allows easy opening and guarantees that the can is kept air- lined shell into a finished end. This work is done in a
tight and tamper proof. Conversion Press and produces a strip of tabs from a narrow
coil of aluminium fed into an integral tab die. It also forms and
In addition to the standard finish, ends can be made in a scores the shell into a recognisable end, and attaches the tab to
variety of colours, with tabs and ends often available in the end.
contrasting colours. Promotional ends are also produced to fulfil
specific customer requirements. These include ends with logos, There are eight separate stages, or progressions involved in
symbols and winning number sequences which can either be converting a shell into a finished end. There are 13 working
printed or incised under the tab. stages involved in producing the Stolle tab and 17 working
stages in producing a DRT tab.
Shells: Can end manufacture begins with a coil of aluminium.
This is fed through a Shell Press, which stamps out and forms Quality: At all stages of the end production process, the ends
the basic Shell. This is the end with no forming, nor tab are constantly scanned by cameras and sophisticated leak
attached, just a flat disc with the outside diameter curled to detection systems. Functional checks are performed by computer
accept a can neck. The Shell process can produce more than controlled equipment, backed up by extensive visual checks.
6,000 shells a minute These tests are essential in confirming the integrity of the
product before the ends are packed into paper sleeves and
Compound: The next stage of the process is the application of palletised for shipment.
a special type of sealant called compound, which is applied to
the inside curl of the shell. This ensures a perfect seal when the
end is seamed onto the can. The process is called Lining, and is
applied at a very high speed on a Compound Lining machine.

BEVERAGE CAN
Europe and Asia
CAN PRODUCT DATA SHEETS
Introduction .... >
Can Size Datasheet .... >

BEVERAGE CAN
Europe and Asia
INTRODUCTION
Product Data Sheets (PDS Sheets) are designed to provide our customers with container specification details required for
filling and processing.
PDS sheets are controlled documents within Rexam and are subject to change without notice.
PDS sheets are available from the local CTS office and, overleaf, current PDS reference numbers are quoted.
The chart overleaf also shows all Can sizes and materials manufactured by Rexam BCE.

BEVERAGE CAN
Europe and Asia
CAN SIZE DATASHEET

PLANT CAPACITY MATERIAL NECK DIAMETER BASE PDS NO.
Enzesfeld 250ml Aluminium 200 200 Stackable C139
(Austria) 500ml Aluminium 206 202 Stackable C130
500ml Aluminium 202 202 Stackable C113
Ejpovice 250ml Aluminium 200 200 Stackable C139
(Czech 330ml Aluminium 206 202 Stackable C122
Republic) 330ml Aluminium 202 202 Stackable C105
Dunkerque 330ml Steel 202 202 Stackable C133
(France) 500ml Steel 206 202 Stackable C160
500ml Steel 202 202 Stackable C134
Berlin 330ml Steel 202 202 Stackable C146
(Germany) 500ml Steel 206 202 Stackable C140
Gelsenkirchen 330ml Steel 202 202 Stackable G1
(Germany)
Recklinghausen 250ml Aluminium 200 200 Stackable C139
(Germany) 296ml Aluminium 200 200 Stackable C148

BEVERAGE CAN
Europe and Asia
CAN SIZE DATASHEET

PLANT CAPACITY MATERIAL NECK DIAMETER BASE PDS NO.
Nogara 250ml Aluminium 206 202 Stackable C116
(Italy) 250ml Aluminium 202 202 Stackable C112
San Martino 330ml Aluminium 206 202 Stackable C101
(Italy) 330ml Aluminium 202 202 Stackable C104
Naro-Fominsk 330ml Aluminium 206 202 Stackable C131
(Russia) 330ml Aluminium 202 202 Stackable C120
La Selva 330ml Steel 202 202 Stackable C144
(Spain)
Valdemorillo 330ml Steel 202 202 Stackable C144
(Spain)
Fosie 330ml Aluminium 206 202 Stackable C122
(Sweden) 330ml Aluminium 202 202 Stackable C105

BEVERAGE CAN
Europe and Asia
CAN SIZE DATASHEET

PLANT CAPACITY MATERIAL DIAMETER BASE PDS NO.
Manisa 330ml Aluminium 206 202 Stackable C122
(Turkey) 330ml Aluminium 202 202 Stackable C105
Milton Keynes 330ml Aluminium 206 202 Stackable C101
(England) 330ml Aluminium 202 202 Stackable C104
Wakefield 330ml Aluminium 202 202 Stackable C104
(England)

BEVERAGE CAN
Europe and Asia
END PRODUCT DATA SHEETS
Introduction .... >
End Size Datasheet .... >

BEVERAGE CAN
Europe and Asia
INTRODUCTION
Product Data Sheets (PDS Sheets) are designed to provide our customers with container specification details required for
filling and processing.
PDS sheets are controlled documents within Rexam and are subject to change without notice.
PDS sheets are available from the local CTS office and, overleaf, current PDS reference numbers are quoted.
The chart overleaf also shows all End sizes and materials manufactured by Rexam BCE.

BEVERAGE CAN
Europe and Asia
END SIZE DATASHEET

PLANT DIAMETER OPENING PDS NO.
Mont 200 Stay-on-Tabs (SOT) E103/E105
(France) 200 Large Opening Ends (LOE) E104
202 Stay-on-Tabs (SOT) E101/E106
202 Large Opening Ends (LOE) E102/E111
206 Large Opening Ends (LOE) E109
Recklinghausen 200 Stay-on-Tabs (SOT) E103/E105

(Germany) 200 Large Opening Ends (LOE) E104
202 Large Opening Ends (LOE) E102/E111
Waterford 202 Stay-on-Tabs (SOT) E113

(Ireland) 202 Large Opening Ends (LOE) E110
Naro–Fominsk 202 Stay-on-Tabs (SOT) E101/E106

(Russia) 202 Large Opening Ends (LOE) E102/E111

BEVERAGE CAN
Europe and Asia
MANUFACTURING CODES AND TRACEABILITY
Can Manufacturing Codes .... >
Other Can Codes .... >
End Manufacturing Codes .... >

BEVERAGE CAN
Europe and Asia
CAN CODES
Every can must be printed with a can code conforming to the following standards
Year Month letter

Last Digit Only Click Here
2 W 3 1 A 01 B Crew or time
Click Here
Country Plant Line Day of month

Click Here Click Here 2 Digits

BEVERAGE CAN
Europe and Asia
Country / Plant Codes

Plant Country Code Plant Code
Milton Keynes, England 2 M
Wakefield, England 2 W
Nogara, Italy 3 N
San Martino, Italy 3 S
Manisa, Turkey 4 M
Berlin, Germany 5 B
Gelsenkirchen, Germany 5 G
Recklinghausen, Germany 5 R
Dunkerque, France 6 D
La Selva, Spain 7 L
Valdemorillo, Spain 7 V
Enzesfeld, Austria 8 E
Fosie, Sweden 9 F
Naro–Fominsk, Russia 10 N
Ejpovice, Czech Republic 11 E

BEVERAGE CAN
Europe and Asia
Can Manufacturing Codes

Month Codes
A = January G = July
B = February H = August
C = March J = September
D = April K = October
E = May L = November
F = June M = December
NOTE : No letter I
Crew or Time Designation
A:
B:
C: REFERS TO MANUFACTURING CREWS OR TIME PERIODS
D:
E:

BEVERAGE CAN
Europe and Asia
OTHER CAN CODES
On the dome of the can other traceability codes may be present The Customer reference code may be positioned towards the
such as: top edge of the can, as above.
• Bodymaker number
• Inside spray identification (colour or ultraviolet)
• Cup number
Precise visualisation of these codes may vary between plants.

BEVERAGE CAN
Europe and Asia
END MANUFACTURING CODES

The following is incised on each end
Plant Code RXM-M = Rexam Mont

RXM-N = Rexam Naro Fominsk
RXM-R = Rexam Recklinghausen
RXM-W = Rexam Waterford
Press and Lane Mont i.e 11B3 = press 11 and lane B3

Naro Fominsk i.e F1 = press F and lane 1
Recklinghausen i.e 1M = press 1 and lane M
Waterford i.e 31B = press 31 and lane B
Date Mont Week period 1-52

Naro Fominsk Week period and Year i.e. 273 = week 27 year 3
Recklinghausen Week period and Year i.e. 2703 = week 27 year 03
Waterford Week period 1-52 for module 4
Month period 1-12 for module 1,2 and 3 as by minute laser coding is used.

BEVERAGE CAN
Europe and Asia
END MANUFACTURING CODES

Laser Coding (Waterford modules 1,2 and 3 only)
As a further development, laser coding is installed on 3 of the manufacturing modules at the Waterford End plant.
The laser code etches the time of manufacturing on each end in a two-tier format, as described below.
The etching is made visible by filling in with a chalk/soft lead pencil or similar.
The upper tier will comprise of six characters, representing the date
and year, i.e.
15 10 03
Day Month Year
The lower tier comprise of five characters which represent the hour
and the minute of production, i.e.
09:37
Hour/Minute

BEVERAGE CAN
Europe and Asia
ARTWORK GUIDELINES
Introduction .... >
Basecoating .... >
Printing .... >
Overvarnish .... >

BEVERAGE CAN
Europe and Asia
ARTWORK GUIDELINES
INTRODUCTION
This section provides information and guidance in the preparation of 2-piece can
artwork and origination. Rexam publishes a Graphics Guide that covers all aspects of
design preparation in greater detail. To obtain a copy of the guide, please contact
your local Technical Services representative, or copies may be obtained from
www.rexam.com
2-PIECE CAN DECORATION PROCESS:

Cans may be printed directly on to the aluminium or steel surface (substrate) or a
basecoat (normally white) may be applied prior to printing. This coating forms the
substrate for printing and also protects the can during filling and distribution. Where
no basecoat is applied, a protective ‘overvarnish’ will be applied over the print.

BEVERAGE CAN
Europe and Asia
ARTWORK GUIDELINES
BASECOATING
Basecoats are generally opaque white or transparent clear. In addition coloured
basecoats may be used, however, these are not recommended due to inherent
problems related to colour consistency of both the basecoat and the printing inks.
Basecoat is applied to the sidewall of the can by high speed, continuous motion
gravure coaters. Material is fed to the gravure roller, which applies a predetermined
film weight of coating to a rubber applicator roll which in turn, applies the basecoat to
the side wall of the can.
The gravure roller surface is etched with a pattern of cells, the size and depth of the
cell governing the amount of basecoat transferred to the applicator roller.
The basecoat is thermally cured by passing the can through a pin chain oven.

BEVERAGE CAN
Europe and Asia
ARTWORK GUIDELINES
PRINTING
The printing process used for 2 piece cans is normally referred to as ‘dry offset’ printing. However, there are a number
of unique features to the process used on 2 piece cans that are not found in other forms of printing.
The customer’s design is divided into a series of separations, each representing a different colour. The number of
separations is limited by the number of inker units available on the can decorator. This process is normally carried out
digitally. ‘Air gaps’ are introduced between each colour to prevent colours mixing during the printing process.
From each separation, a negative film is produced, which in turn is used to make a relief
printing plate using a photopolymer material backed by steel.
Printing plates are mounted into the can decorator on magnetic print cylinders. The
position of the plates is accurately controlled by means of location holes in the plates and
ground pins in the cylinders.

BEVERAGE CAN
Europe and Asia
ARTWORK GUIDELINES
PRINTING
Each plate is supplied with ink from a fountain, via a series of rubber and steel rollers. The amount of ink applied can
be adjusted to suit the image being printed. All inks are ‘special colours’. It is not possible to use standard process inks
for 2-piece can printing.
At the centre of the can decorator is a blanket drum which carries up to 12 compressible
rubber faced printing blankets. As the blanket drum rotates, each blanket picks up ink
from each of the printing plates in turn so that a complete image, in reverse, is assembled
on each blanket. The air gaps introduced during the reproduction process prevent the inks
from contaminating each other.
The can is presented to the blanket, mounted on a supporting mandrel that is free
to rotate and follows the profile of the blanket drum. As the can ‘rolls’ over the
surface of the blanket, the complete image (all colours) is transferred to the can wall in a
single operation. The spindle drum carrying the cans rotates at a constant speed.

BEVERAGE CAN
Europe and Asia
ARTWORK GUIDELINES
OVER VARNISH
Where necessary, the design is ‘overvarnished’ immediately after printing. The application system is similar to
basecoat application.
Overvarnish serves to protect the printing inks and the can surface. It also enhances the gloss of the design and
provides excellent can-to-can mobility characteristics.
The printed image and overvarnish are thermally cured by passing the can through a pin chain oven.
SPECIAL REQUIREMENTS
The unique feature of the 2-piece can printing process; common offset blanket and continuous motion; place special
requirements on designs to be printed on 2-piece cans.
Special requirements are also necessary for bar code application of the can.
Full details of these requirements can be obtained from Rexam Graphics Guide or by contacting your local Rexam
graphics department.

BEVERAGE CAN
Europe and Asia
PALLET SPECIFICATION FOR CANS AND ENDS
Standard Pallet Configurations and Weights .... >
Returnable Packing Materials .... >
Drawings .... >
Can Layer Patterns .... >

BEVERAGE CAN
Europe and Asia
EXAMPLE OF CAN PALLET ASSEMBLY

Illustration shows four way entry pallet and timber top frame.
Banding illustration shows 3x2 but 2x2 is also used,

depending on the pallet dimensions required.
Pallets of cans are supplied in the format shown. The

material used for pallets is plastic or wood and for top
frames, plastic, wood or metal is used. The pallet size or
height can vary, depending on the customers requirements.
External protection can also be provided if required by

agreement in the form of stretchwrap.

BEVERAGE CAN
Europe and Asia
STANDARD PALLETS FOR CANS

PLANT: FOSIE - Aluminium Cans
PALLET DIMENSION CAN SIZE NUMBER CAN LAYER CANS PER NOMINAL TOP FRAME/PALLET
mm Length x Width ml OF LAYERS CONFIGURATION MATERIAL
Length x Width LAYER PALLET HEIGHT WEIGHT, kg
(Number of cans) mm ALU STEEL
1350x1200 330 22 23x17 391 8602 ~2730 ~155 Wood/Wood
SWEDISH 500 15 23x17 391 5865 ~2710 ~135
1250x1180 330 23 18x20 360 8280 ~2825 ~155 Steel/Wood

GERMAN 500 16 18x20 360 5760 ~2840 ~135 Steel/Plastic
1420x1120 330 22 20x19 380 8360 ~2700 ~145 Wood/Wood

DUTCH/SPAIN 500 15 20x19 380 5700 ~2680 ~135 Steel/Wood
Steel/Plastic
Plastic/Plastic
1440x1120 330 18 21x19 399 7182 ~2235 ~130 Wood/Wood

ITALIAN 500 14 21x19 399 5586 ~2510 ~130

BEVERAGE CAN
Europe and Asia

PLANT: RECKLINGHAUSEN – Aluminium Cans
1250x1180 150 26 22x25 550 14300 ~2460 ~165 - Steel/Wood or Plastic
GERMAN 200 20 22x25 550 11000 ~2380 ~155 -
250 19 22x25 550 10450 ~2700 ~150 -
330 23 18x20 360 8280 ~2820 ~155 -
355 17 18x20 360 6120 ~2235 ~125 -
1420x1120 150 27 25x23 575 15525 ~2560 ~170 - Wood/Wood or Plastic

DUTCH/SPAIN 330 23 20x19 380 8740 ~2820 ~155 -
355 17 20x19 380 6640 ~2240 ~130 -

ENGLISH 200 21 23x23 529 11109 ~2510 ~150 -
250 18 23x23 529 9522 ~2585 ~140 -
330 22 18x19 342 7524 ~2716 ~140 -
1350x1200 330 22 19x20 380 8360 ~2730 ~150 - Wood/Wood

SWEDISH

BEVERAGE CAN
Europe and Asia

PLANT: MANISA – Steel (330ml only) and Aluminium Cans (330ml and 500ml only)
1420x1120 330 22 20x10+21x9 389 8558 ~2715 ~155 ~280 Wood/Plastic
DUTCH/SPAIN 500 15 20x10+21x9 389 5835 ~2700 ~145 - Wood/Plastic

BEVERAGE CAN
Europe and Asia

PLANT: MILTON KEYNES - Aluminium Cans
1250x1180 440 15 18x20 360 5400 ~2397 ~128 - Steel/Wood
GERMAN 500 15 18x20 360 5400 ~2670 ~135 -
568 13 18x20 360 4680 `2600 ~130 -
1420x1120 330 23 20x10+21x9 389 8947 ~2835 ~160 - Plastic/Wood or Plastic

DUTCH/SPAIN 500 15 20x10+21x9 389 5835 ~2690 ~140 -
568 11 20x10+21x9 389 4279 ~2244 ~120 -
440 17 20x10+21x9 389 6613 ~2720 ~145 -
1300x1120 275 25 19x9+18x10 351 8775 ~2664 ~155 - Plastic/Plastic

ENGLISH 330 23 19x9+18x10 351 8073 ~2835 ~145 -
375 19 19x9+18x10 351 6669 ~2660 ~140 -
440 17 19x9+18x10 351 5967 ~2731 ~135 -
500 15 19x9+18x10 351 5265 ~2700 ~130 -
568 13 19x9+18x10 351 4563 ~2625 ~125 -
1350x1200 440 17 19x10+20x10 390 6630 ~2720 ~145 - Wood/Wood

SWEDISH 568 11 19x10+20x10 390 4290 ~2230 ~120 -

BEVERAGE CAN
Europe and Asia

PLANT: WAKEFIELD – Aluminium Cans
1250x1180 330 22 18x20 360 7920 ~2710 ~145 - Steel/Wood or Plastic
GERMAN
1420x1120 330 23 20x10+21x9 389 8947 ~2860 ~160 - Wood or Plastic/Wood

DUTCH/SPAIN or Plastic
1300x1120 330 23 19x9+18x10 351 8073 ~2860 ~145 - Plastic/Plastic

ENGLISH
1350x1200 330 22 19x10+20x10 390 8580 ~2720 ~150 - Wood/Wood

SWEDISH

BEVERAGE CAN
Europe and Asia

PLANT: EJPOVICE – Aluminum Cans
1350x1200 330 23 20x19 380 8740 ~2820 ~155 - Steel/Plastic
SWEDISH 500 16 20x19 380 6080 ~2890 ~140 - Wood/Plastic
1250x1180 330 23 18x20 360 8280 ~2820 ~155 - Steel/Plastic

GERMAN 500 16 18x20 360 5760 ~2880 ~135 - Wood/Plastic
250 19 22x25 550 10450 ~2696 ~150 -
1420x1120 330 23 20x19 380 8740 ~2820 ~155 - Steel/Plastic

DUTCH/SPAIN 500 16 20x19 380 6080 ~2880 ~140 - Wood/Plastic
250 18 25x23 575 10350 ~2560 ~150 -
1300x1120 330 23 18x19 342 7866 ~2820 ~150 - Steel/Plastic

ENGLISH Wood/Plastic

BEVERAGE CAN
Europe and Asia

PLANT: DUNKERQUE - Steel Cans
1250x1180 330 23 18x20 360 8280 ~2825 - ~270 Steel/Wood or Plastic
GERMAN 500 16 18x20 360 5760 ~2860 - ~240
1420x1120 330 23 20x10+21x9 389 8947 ~2825 - ~285 Plastic or Wood/Wood

DUTCH/SPAIN 330 23 20x10+20x9 380 8740 ~2825 - ~280 or Plastic
500 15 20x10+21x9 389 5835 ~2690 - ~240
1300x1120 330 22 19x9+18x10 351 7722 ~2725 - ~250 Plastic/Plastic

ENGLISH 500 15 19x9+18x10 351 5265 ~2700 - ~220

BEVERAGE CAN
Europe and Asia

PLANT: BERLIN - Steel Cans
1250x1180 330 23 18x20 360 8280 ~2810 - ~275 Steel/Plastic
GERMAN 500 16 18x20 360 5760 ~2840 - ~245 Wood/Plastic
1420x1120 330 22 19x20 380 8360 ~2722 - ~280 Steel/Plastic

DUTCH/SPAIN 500 15 19x20 380 5700 ~2700 - ~245 Wood/Plastic
1350x1200 330 22 19x20 380 8360 ~2730 - ~280 Wood or Steel/Wood

SWEDISH 500 15 19x20 380 5700 ~2710 - ~245

BEVERAGE CAN
Europe and Asia

PLANT: VALDEMORILLO - Steel Cans
DUTCH/SPAIN

BEVERAGE CAN
Europe and Asia

PLANT: LA SELVA – Steel Cans
DUTCH/SPAIN

BEVERAGE CAN
Europe and Asia

PLANT: NOGARA– Aluminium Cans
1420x1120 250 26 20x19 380 9880 ~2555 ~155 - Wood/Wood
DUTCH/SPAIN
1440x1120 250 26 21x19 399 10374 ~2570 ~160 - Wood/Wood

ITALY
1420x1120 330 21 20x19 380 7980 ~2600 ~145 - Wood/Wood

DUTCH/SPAIN
1440x1120 330 21 21x19 399 8379 ~2600 ~150 - Wood/Wood

ITALY

BEVERAGE CAN
Europe and Asia

PLANT: SAN MARTINO – Aluminium Cans
1420x1120 330 21 20x19 380 8336 ~2600 ~150 - Wood/Wood
DUTCH/SPAIN
1440x1120 330 22 21x19 399 8778 ~2700 ~155 - Wood/Wood

ITALY 500 14 21x19 399 5586 ~2645 ~135 -
500 12 21x19 399 4788 ~2174 ~120 -

BEVERAGE CAN
Europe and Asia

PLANT: ENZESFELD – Aluminium Cans
1250x1180 250 19 22x25 550 10450 ~2700 ~155 - Steel/Wood
GERMAN 330 23 18x20 360 8280 ~2810 ~150 -
500 16 18x20 360 5760 ~2840 ~135 -

DUTCH/SPAIN 330 22 20x19 380 8360 ~2710 ~150 -
500 15 20x19 380 5700 ~2690 ~135 -
1440x1120 500 14 21x19 399 5586 ~2570 ~130 - Wood/Wood

ITALY
1200x1000 500 12 17x17 289 3468 ~2170 ~100 - Wood/Wood

BEVERAGE CAN
Europe and Asia

PLANT: NARO FOMINSK- Aluminium Cans
1250x1180 330 18 18x20 360 6480 ~2240 ~130 - Wood/Steel
GERMAN 500 13 18x20 360 4680 ~2370 ~115 - Wood
1350x1200 330 21 19x10+20x10 390 8190 ~2615 ~150 - Wood/Wood

SWEDISH 500 14 19x10+20x10 390 5460 ~2540 ~125 -
1420x1120 500 12 10x20+9x21 389 4668 ~2170 ~112 - Wood/Wood

DUTCH/SPAIN

BEVERAGE CAN
Europe and Asia
STANDARD PALLETS FOR ENDS – 50mm (200)
PLANT
MONT RECKLINGHAUSEN
ITEM
PALLET SIZE, mm 1000x1200 1000x1200
PALLET HEIGHT, mm 1700 1700
ENDS PER BAG 585 585
BAGS PER LAYER 16/+15 on top 16/+15 on top
BAGS PER PALLET 511 511
ENDS PER PALLET 298935 298935
PALLET WEIGHT, kg 900 900

BEVERAGE CAN
Europe and Asia
PLANT
WATERFORD MONT RECKLINGHAUSEN NARO FOMINSK
ITEM
PALLET SIZE, mm 1000x1200 1000x1200 1000x1200 1000x1200
PALLET HEIGHT, mm 1730 1730 1730 1645
ENDS PER BAG 600 600 585 575
BAGS PER LAYER 16 16 16+15 0n top 16
BAGS PER PALLET 480 480 479 448
ENDS PER PALLET 288000 288000 280215 257600
PALLET WEIGHT, kg 950 950 950 910

BEVERAGE CAN
Europe and Asia
PLANT
MONT
ITEM
PALLET SIZE, mm 1000x1200
PALLET HEIGHT, mm 1760
ENDS PER BAG 585
BAGS PER LAYER 15/14
BAGS PER PALLET 392
ENDS PER PALLET 229.320
PALLET WEIGHT, kg 925

BEVERAGE CAN
Europe and Asia
RETURN PACKAGING – PALLETS
PALLETS
• Stack pallets neatly immediately after depalletising
• Stack on vehicle, in regular quantities, up to 18 high
• DO NOT mix pallets from different owners
• DO NOT mix wooden and plastic pallets
TOP FRAMES
A maximum of 50 wooden or plastic top frames should
be stacked squarely on to a can pallet.
• Band to the pallet for safe transit.
• In some countries, both steel and plastic top frames are
✓
THIS IS OK
✘
THIS IS NOT OK
automatically stacked on top of the empty pallet
(see above). Where this is the case, they should not be
stacked more than 17 high.
• DO NOT mix top frames from different owners.
• DO NOT mix wooden, plastic or steel top frames.

BEVERAGE CAN
Europe and Asia
RETURN PACKAGING – LAYER PADS
Bands Topframe
LAYER PADS
• Layer pads should be stacked squarely on to a can pallet.
400mm – To a maximum height of 200mm on plastic layer pads.
– To a maximum height of 400mm on cardboard layer pads.
• Place a top frame on top of the stack, band together with
two bands.
• Layer pads should be stored inside prior to return.
✓
THIS IS OK
✘
THIS IS NOT
• DO NOT mix cardboard and plastic layer pads.

BEVERAGE CAN
Europe and Asia
STANDARD PALLETS FOR CANS AND ENDS
DRAWING NO TITLE SIZE(mm) VERSION

RS290B-D1001 D German Wooden Pallet 1250x1180 D Z Click Here For Drawing
RS290B-D1003 D Swedish Wooden Pallet 1350x1200 D Z Click Here For Drawing
RS290B-D1004 D Dutch Wooden Pallet 1420x1120 D Z Click Here For Drawing
RS290B-D1005 D Dutch One Way Wooden Pallet 1420x1120 D Z Click Here For Drawing
RS290B-D1014 D German Plastic Pallet 1250x1180 D Z Click Here For Drawing
RS290B-D1015 B Dutch Plastic Pallet 1420x1120 B Z Click Here For Drawing
RS290B-D1015 C Dutch Plastic Pallet 1420x1120 C Z Click Here For Drawing
RS290B-D2098 A English Plastic Pallet 1300x1120 A Z Click Here For Drawing
RS290B-D2097 A Standard Plastic End Pallet 1200x1000 A Z Click Here For Drawing

BEVERAGE CAN
Europe and Asia
STANDARD TOP FRAMES FOR CANS
DRAWING NO TITLE SIZE(mm) VERSION

RS290B-D1011 A Dutch Wooden Frame 1420x1120 A Z Click Here For Drawing
RS290B-D1007 A Dutch Steel Frame 1435x1135 A Z Click Here For Drawing
RS290B-D1012 A German Wooden Frame 1250x1180 A Z Click Here For Drawing
RS290B-D1010 A Swedish Wooden Frame 1350x1200 A Z Click Here For Drawing
RS290B-D1008 A German Steel Frame 1265x1195 A Z Click Here For Drawing

BEVERAGE CAN
Europe and Asia
CAN LAYER PATTERNS
DRAWING NO TITLE SIZE VERSION

RS290A-D2152 A UK Pallet pattern (351 cans per layer) 1120x1300 A Z Click Here For Drawing
RS290A-D2152 A Italian Pallet Pattern (399 cans per layer) 1120x1440 A Z Click Here For Drawing
RS290A-D2153 A Dutch/Spanish/Turkish (380 cans per layer) 1120x1420 A Z Click Here For Drawing
RS290A-D2153 A Dutch/Spanish/Turkish (389 cans per layer) 1120x1420 A Z Click Here For Drawing
RS290A-D2155 A Scandinavian (390 cans per layer) 1200x1350 A Z Click Here For Drawing
RS290A-D2155 A German (360 cans per layer) 1180x125 A Z Click Here For Drawing

BEVERAGE CAN
Europe and Asia
LABELS FOR CAN AND END PALLETS
Can Pallet Labels .... >
End Pallet Labels .... >

BEVERAGE CAN
Europe and Asia
CAN PALLET LABELS 14
3
1 Manufacturing Plant 14 Pallet no. in numbers & EAN128
1 2
2 Production line (Full) 15 Pallet number code, 4
(If applicable) 7
3 Production line (Short)
16 Standard Remark 12 5 6 9 10 11
4 Pallet number (Short) Instruction to customer
5 Can size 17 Customer References 13 15
6 Dimension body/neck (Different requirements for customers) 17 14 18
7 Article name
18 Packaging code
(If applicable)
8 Customer 19 EAN and SSCC code incl.
9 Number of layers human readable line, EAN128C 19
(Both barcodes are configurable to
10 Cans on pallet customers specific requirements).
11 Production times/date
12 Article number 16
13 Production batch number

Z Click Here To Zoom In

BEVERAGE CAN
Europe and Asia
END PALLET LABELS

1 Manufacturing plant 14 TAB description
1 2 3
2 Conversion press 15 Drink type 4 6 7
3 Lanes from the C/P 16 Customer reference 5 8
4 Article name 17 Sleeve (taped or un-taped) 10 9
11 12
5 Ends on pallet 18 Design number 15
13 14 22
6 End type 19 Production time/date 17 19
16
7 Material thickness 20 EAN and SSCC code incl. 18
8 Compound placement human readable line, EAN128C

(Both barcodes are configurable to
9 End dimension customers specific requirements).
20
10 Article number
21 Sleeves on pallet
11 Batch number
12 Additional material description
13 Pallet number

BEVERAGE CAN
Europe and Asia
QUALITY CRITERIA
Classification of defects .... >
Can defects definition .... >
End defects definition .... >

BEVERAGE CAN
Europe and Asia
CLASSIFICATION OF DEFECTS
If you have any questions regarding the Can and End 1. Critical Defects
performance or quality please contact your local CTS Critical defects are defined as those that:
Engineer and supply him with all the details you have, to a) Affect the quality of the package in terms of
assist him in assessing the situation. leakage or spoilage.
b) Cause excessive interruption of production and
Please help us to help you by providing. grossly reduce filling line efficiency.
c) Occur at a level where information required by
• The manufacture date of the component.
law is illegible or missing.
• The pallet ticket number. d) Internal contamination.
• A number of indicative samples.
2. Other Defects
Attribute Defect Descriptions Other defects are considered non–critical.
The attribute defect descriptions listed on the following
pages have been prepared to avoid misunderstanding in
terminology and defect severity.

BEVERAGE CAN
Europe and Asia
TWO–PIECE CANS CRITICAL DEFECT DESCRIPTIONS

CRITICAL DEFECT DESCRIPTION EFFECT
Lamination A condition where the steel base separates in to two or more discreet layers Any Degree
due to inclusions, impurities, gas pockets etc.
Pin Hole A perforation in the metal which will allow the passage of product Any Degree
through it.
Severe Damage/Fractures Buckling, denting or fracture. Where the can would cause hold–ups or
leakage on a customer’s filling line.
Split Pleats Where the neck of the can shows a fold in the metal which has split. Any Degree
Trim on Flange When slivers of metal from the trimming operation are left on the flange. Any Degree
Split Flange A fracture of the metal around the periphery of the flange parallel to the Where the depth of the split exceeds half
radii of the open end. the flange width
Flange Defects Deformation of the flange. Where the degree of deformation prevents
the formation of a satisfactory double seam
Mis–Sprays Incomplete internal lacquer or missing areas of lacquer. Any Degree
Contamination Foreign matter inside the can. Where material is easily visible and is not
removed during washing and processing
Defective Text Where there is a critical text defect on the printed design. Where information required by law is
missing or illegible
Wrong Specification Mixed designs on same pallet Any Degree

BEVERAGE CAN
Europe and Asia
EASY OPEN ENDS CRITICAL DEFECT DESCRIPTIONS

CRITICAL DEFECT DESCRIPTION EFFECT
Pin Hole A pin hole in any part of the end due to defective material Any Degree
Curl Damage Deformation of the curl Where the degree of deformation prevents
the formation of a satisfactory double seam
Gaps in Breaks in the continuity of the lining compound To the degree where leakage will occur
Compound Lining
End Fracture Damaged end To the degree where leakage will occur
Fractured Score A condition where the score is cracked To the degree where leakage will occur
Rivet Fracture Where the rivet is cracked Any Degree
Tab Failure/Missing Where the tab fails or is not present Any Degree
Contamination Foreign matter adhering to the inside of the end Where material is easily visible and is not
removed during processing
Wrong Specification Mixed designs on the same pallet Any Degree
The defect descriptions are based around acceptable industry standards and, after discussion with your Rexam
representative, could be the basis for agreement on Acceptable Quality Levels (AQL) values.

BEVERAGE CAN
Europe and Asia
PRODUCT FORMULATION AND TEST PACKS
Test Packs .... > Sample Evaluation .... >
Test Requirements .... > Product Warranty .... >
Filling Trials .... >

BEVERAGE CAN
Europe and Asia
TEST PACKS
SCOPE
The information below applies throughout Rexam Beverage Can Europe and Asia.
PURPOSE
This section has been devised to ensure that any Cans and Ends supplied to the
customer are compatible with the products that they are intended to contain over the
agreed warranty period, without any adverse effects on taste or colour of the contents
or integrity of the container.
The container/product combination should also meet any customer requirements

regarding metal pick-up limits over the agreed test period.

BEVERAGE CAN
Europe and Asia
TEST PACKS
TEST REQUIREMENTS
The requirement for test-packing a product may originate from a number of sources and may be required whenever a
change in manufacturing or filling conditions, or contractual obligations occur. The requirement to test pack may be
instigated either by the customer or by Rexam Beverage Can.
Generally, the main reasons for test packs are as follows, although this list is not exhaustive:-
· New product introduction (customer or Rexam)

· Formulation changes to current products
· Changes to agreed warranty period
· New plants, lines, materials and process changes
· Qualification of alternative materials (New Can/End lacquers or End compounds)
The need to test pack through filling trials will be agreed upon discussion between the customer and CTS.
Changes to product formulation not advised to Rexam could invalidate the warranty.

BEVERAGE CAN
Europe and Asia
TEST PACKS
FILLING TRIALS
Any filling trial should, if possible, take place on the customer’s normal production line. Filling conditions should be
identical to those for standard products. Where appropriate, it is important that
when testing new Can or End developments that a similar quantity of "control" Note: In cases where a new
product is being filled for the first time,
Cans, taken from customer’s normal production, (which may be either Rexam or
or upon warranty changes, there will
competitor products) are filled as a direct comparison to test samples. This will clearly not be controls for comparison
show whether the new product is more or less aggressive than the original product. unless competitor’s product is available.
The bottled sample will serve for use as

The number of test cans required will depend on both the sensitivity (or the "immediate" test specimen as it will
aggressiveness) of the product and the specific test requirements agreed with the most closely resemble the product at
customer. The following is a list of Rexam’s requirements for each filling test. filling (being more inert in nature than
Cans or Ends).
Ideal requirement – Rexam (in addition to any customer requirements)

The customer may also require a
6 x 24 Can packs of trial product (minimum 4 x 24 cans) number of samples for independent
6 x 24 Can packs of controls (if applicable) (minimum 4 x 24 cans) analysis. This should be established
1 x 1 Litre bottled sample of product prior to the trial so that sufficient empty
cans are available.
1 x 24 Can pack of empty test cans*
12 x loose ends* * retained by originator

BEVERAGE CAN
Europe and Asia
TEST PACKS
SAMPLE EVALUATION
Samples are normally stored upright and inverted at both ambient and elevated temperatures(37oC) and monitored at
predetermined intervals for metal pick up. Evaluation is conducted primarily to ensure that there is no incompatibility
which would result in a major functional failure such as perforation, as well as confirming the warranty.
PRODUCT PERFORMANCE
CTS will advise of the results of the test pack to the nominated customer contact Note: It is the responsibility of the customer
to satisfy themselves that desirable product
in writing, giving details of the warranty period granted, copying the relevant qualities, such as aroma and taste, remain
Account Manager. acceptable for the intended life of the drink.

BEVERAGE CAN
Europe and Asia
TEST PACKS
PRODUCT WARRANTY
Product will normally be guaranteed for up to 12 months from the date of filling,
Note: Changes to the product
provided the test pack guidelines and filled goods storage handling practices have formulation will invalidate the warranty
been followed. Exceptions are where a shorter period is necessary, either when test and all changes should be notified in
data is incomplete, or where testing has been completed but indicates that 12 writing to the Rexam Beverage Can
CTS Department with sufficient notice to
months life may not be commercially achievable. allow for evaluation.
The warranty is based upon the presence of a legible filling date code and exclusion of air during filling. The air
content must not exceed 2ml per can (or an equivalent volume of oxygen; 0.4ml).

BEVERAGE CAN
Europe and Asia
CAN HANDLING/PASTEURISATION
Typical Can Filling Line Layout .... > Filled Can Handling .... >
Fork Lifts .... > Storage .... >
Empty Can Handling .... > Transport .... >
Filling and Seaming .... > Primary and Secondary Corrosion .... >
Pasteurisation .... > Tab and Dome Staining .... >

BEVERAGE CAN
Europe and Asia
TYPICAL CAN FILLING LINE LAYOUT

FILLER
END FEED GRAVITY RINSER SINGLE FILER VACUUM TRANSFER MECHANICAL MASS TRANSFER
DEPALLETISER
PASTEURISER/
COARSE TWIST CAN WARMER
FILL CHECK & RINSE
SEAMER
ACCUMULATION TABLE
FINAL AIR BLOWER ELEVATOR

AIR BLOWER FOR FILL CHECK FOR BASE OF CANS PALLETISER PALLET STRETCH WRAPPER
END AND CAN BODY TWIST & END RINSER
CODER
SHRINK TUNNEL
TRAY LOADER
SHRINK WRAP

BEVERAGE CAN
Europe and Asia
EMPTY CAN HANDLING
FORK LIFTS
Careful Fork Lift Truck handling is essential for a good delivery of both empty and filled Can goods.
Damaged Cans could be the result of misaligned placement/stacking of Can pallets during unloading or loading.
This practice could cause pallets to come in to contact with one another and create Can damage.
There is also a risk that protruding layer pads could cause side wall damage if pallets come in to contact with one
another.
The rear guard on the Fork Lift Truck could present a risk of Can damage if the pallet is tilted sharply backwards. Care
must be taken during this operation.
Any visible signs of Can damage on the outside faces of empty Can pallets must be removed prior to them being
placed on the line. Failure to do so will result in line jams or filler/seamer crashes.
Training of the Fork Lift truck drivers is essential to eliminate the above occurring.

BEVERAGE CAN
Europe and Asia
EMPTY CAN HANDLING
DEPALLETISER TO RINSER
Pallets of Cans are usually transported in to the depalletiser hoist by means of a driven roller or chain conveyor system.
The layer pad grippers should be positioned to grip the layer pad in the void created by the Can layer formation.
The depalletiser sweep mechanism should be as smooth as possible, as sharp movements could cause Can damage and
fallen Cans.
It is recommended that there is no greater than a 5mm drop from the layer of Cans on to the depalletiser
deadplate/conveyor. It is also recommended that the deadplate should be wide enough to hold four rows of Cans. This
will provide Can support for each layer being depalletised and reduce the risk of fallen Cans.
The deadplate should be fixed with countersunk screws ensuring that the cans transfer smoothly without any
projections on the deadplate.

BEVERAGE CAN
Europe and Asia
EMPTY CAN HANDLING
The Can conveyor belt from the depalletiser hoist should preferably be plastic. If any Cans fall over they must be
removed or placed upright using a plastic coated hook, this prevents damaging the internal lacquer. For hygiene
reasons, fingers should not contact the inside of the Cans.
Mass packs are preferred to single conveyors for transportation of Cans to the filler from the depalletiser conveyor, this
optimises the storage capacity for a constant Can flow and reduces the risk of Can damage.
A vacuum transfer unit can be placed on the mass conveyor system just prior to the single filing of Cans to the filler. This
unit will remove fallen Cans from the mass pack, eliminating single filer Can jams.
It is recommended that all conveyor side guides are of a flat faced plastic covered type, and positioned near the base
and neck/shoulder of the Cans, away from the mid wall. Round/”D” section guides should be avoided as they will
cause side wall damage to the Cans.
The combining of Cans from mass pack to single file must be carried out smoothly, over the maximum possible distance
to maximise Can mobility, thus minimising the risk of Can damage.

BEVERAGE CAN
Europe and Asia
EMPTY CAN HANDLING
Twists and in-feeds should, like the side guides, be plastic covered for low friction and have no sharp corners or protrusions.
In–line twists and drop twists should be as long as practical to maximise line mobility and minimise Can damage.
The angle of incline of any empty Can conveyor should not exceed 5 degrees either up or down.
With careful design and line controls, the pressure between Cans should be reduced to a minimum to ensure adequate
Can flow.
Air conveying has proven to be efficient in this respect, particularly with single filers on high speed installations.

BEVERAGE CAN
Europe and Asia
EMPTY CAN HANDLING
RINSER INSTALLATIONS
The established method of rinsing empty beverage Cans is by a pressurised water flush through a gravity rinser.
Sometimes an additional so called "dry box" working with deionised air is installed prior to the water rinse, in order to
remove lightweight debris.
The gravity rinser should be operated with clean water. There is no need for chlorination, unless to secure the
microbiological status of the water itself, and the level should not exceed 5 ppm chlorine.
To operate smoothly, the drop angle should be a minimum of 35 degrees and the drain angle 145 degrees, with a final
180 degree turn to avoid water retention in the Can neck area.
The length of the water spray section should be calculated to give a 2 second efficient rinse time.
The water nozzles should be directed towards the direction of Can flow to assist the Cans through the rinsing section.

BEVERAGE CAN
Europe and Asia
FILLING AND SEAMING
The empty Can conveyer system should run primed and the control of can flow into the filler is achieved by a Can
stop mechanism.
There are various types of Can stops such as star wheels and moveable side guides. Whatever the type, they must be
set up correctly to prevent Can damage occurring.
The use of extensions to Can support brackets under the filling valve is recommended to increase Can stability.
Filling valve Can flange seals should be regularly inspected for wear marks/damage and replaced as necessary.
All drive chains, gears and couplings should have minimum backlash, as excessive backlash has an adverse effect on
Can control, particularly on aluminium Cans.

BEVERAGE CAN
Europe and Asia
FILLING AND SEAMING
Most modern fillers, irrespective of whether they are fill level controlled or volumetric fillers, are static line fillers with no
lifting of the cans, instead, the filling head moves down onto the can applying moderate pressure. Depending on the
filling parameters such as temperature and carbonisation, it is generally in the range of 400 – 600 N.
Lifter type fillers are more critical in this respect and it is possible for the vertical load on the cans to approach close to
their column strength, with possible damage to the flange, which may result in incomplete end seaming or collapsed cans.
A positive can stop such as a mechanical cam on the lifter assembly will control the upward travel of the can flange into
the sealing rubber and avoid this problem.
The snift valve timing must also be correctly maintained. If it releases the can pressure too early, the can may collapse, or if
too late, an excessive amount of contents will be forced out of the can as it leaves the filling valve.
The filler seamer transfer strip should be manufactured using a low friction material and be adequately lubricated by non
corrosive conveyer lubes. The lubricant should be fed on to the top of the transfer strip by a continuous flow feed from a
well, countersunk in to the transfer strip.

BEVERAGE CAN
Europe and Asia
FILLING AND SEAMING
A similar lubrication system should be installed to the filler discharge plate and seamer infeed deadplate.
With the smaller base profile diameters on modern cans, it is important that the base plate diameter is only slightly
larger than the can base, again with the purpose of helping to centralise the cans and thus improve can control.
Modern seamers have driven base plates which is ideal. Free-turning base plates, which rely upon the seaming chuck to
drive the can and end during the seaming operations, are not recommended.
The seaming chuck wall surface should be sufficiently rough to give a positive drive to the end during the seaming
operation. If not, the result may be an incomplete seam formation, skidders and leaking seams.
Other improvements include ceramic or titanium coated seaming rolls, which result in lower friction at the seam
formation and helps to prevent aluminium build up in the roll profile.
With modern beverage cans, it is important to avoid excessive base plate pressure.
For the seamer set up and seam control, refer to the separate "Seam Control Manual" and the Seam Specifications.

BEVERAGE CAN
Europe and Asia
FILLING AND SEAMING
The under cover gasser on the seamer introduces carbon dioxide or nitrogen between the Can and End, prior to
closing during the seaming operation. The purpose of the undercover gassing operation is to minimise the air in the
headspace replacing it with carbon dioxide/nitrogen, whichever is used. This will reduce the possible oxygen pickup
in to the filled product, which has an adverse effect on the long term taste of the product and increase its corrosive
effect on the Can. The maximum amount of air should not exceed 2ml per Can.
Analysis of gas absorption is made by Burette sampling, commonly referred to as the Zahm Nagel Method. If
Nitrogen gas is used for non carbonated product, the analysis has to be carried out by gas chromatography. The
efficiency of the under cover gasing system itself can be checked by a salt water test, where sample Cans are filled to
their nominal volume with a saturated salt (NaCl) solution, seamed and then analysed as above. As there is no gas
pressure from the salt water solution, the can has to be squeezed to get the gas in to the Burette. The maximum
remaining air on this test should not exceed 0.3ml.

BEVERAGE CAN
Europe and Asia
FILLING AND SEAMING
Please refer to instructions from your seamer manufacturer for the settings on the under cover gassing system.
The in-can residual air content must be maintained below 2mls otherwise this may invalidate the can warranty.
Where there is an automatic end feed system to the seamer, it is important that the following is achieved under
normal running conditions.
1. On the end supply system to the seamer, the settings and line controls should give an adequate pressure to
maintain a consistent flow of ends to the gap sensor without over pressurising. If this is not achieved, curl damage
to the end could occur.
2. The gap sensor should be set to control the flow of ends to the end infeed(s) on the seamer, such that the ends are
fed under gravity in to the scroll(s). If this is not achieved, damage could occur to the end, resulting in misfeeds
and potential seaming defects, as well as efficiency issues.

BEVERAGE CAN
Europe and Asia
FILLING AND SEAMING
Where product is chilled prior to filling, the filled Cans need to be raised to a temperature above the dew point, in order
to avoid condensation in filled stock. This is normally achieved by the use of a Can warmer or pasteuriser.
Some modern fillers are able to fill high carbonation beverages at ambient temperatures, which gives less risk of
condensation. Filling lines equipped with this type of filler are often operated without further Can warming, unless the
product itself requires heat treatment for extended shelf life. In processes where there is no use of a Can Warmer or
Pasteuriser, the fill product temperature must be above the dew point temperature, which can be calculated by the use of
the traditional Mollier diagram.
Cans are normally inverted after the seamer to assist in the detection of seam or End leaks. This is normally achieved by
a drop twist turning the Cans through 180°. At this point, the can end should be thoroughly rinsed to remove any
product or track lubricant residues to minimise the risk of stress corrosion. If this is carried out, it will also minimise the
biological loading on the Can warmer/pasteuriser.
The water for rinsing can be taken from the empty Can rinser, thus lowering the consumption of water.

BEVERAGE CAN
Europe and Asia
PASTEURISATION
This section is to briefly explain the Pasteuriser and the Pasteurisation process for Beer and Beverage Cans.
PRINCIPLE OF THE PASTEURISATION PROCESS:

The purpose of the pasteuriser is to maximise the shelf life of drinks contained in Beverage Cans. This is achieved by a
heat treatment process whereby the harmful microbiological organisms are killed by the heat. The treatment is controlled
in such a way that there will be a minimum effect on the physical stability and flavour of the Can contents, together with
a maximum extension of biological stability. When this is achieved, there will be an increased shelf life of the product
contained in the Cans.
THE PASTEURISATION PROCESS INVOLVES THREE STAGES:

1. Gradual heating of the beverage in the filled Cans from the filling temperature to the pasteurisation temperature.
2. The actual pasteurisation, where the Cans are kept at the pasteurisation temperature for a certain time (holding time),
giving the required pasteurisation effect.
3. Gradual cooling of the beverage Cans to the desired discharge temperature.

BEVERAGE CAN
Europe and Asia
PASTEURISATION Note: As the cans are usually

pasteurised upside down, the
In modern pasteurisers, the heat treatment is performed by spraying hot water (at domes become filled with
different regulated temperatures in the various water tanks/zones) on to the filled Cans pasteuriser water.
as they pass through the pasteuriser tunnels.
It is extremely important that the
DESCRIPTION OF THE PASTEURISER: air knives remove this water as
the cans exit the pasteuriser.
The pasteuriser consists of a tunnel, water tank system and temperature control.
Failure to do this, will result in
problems with the printing of
There can be one, two or multi tunnels on a pasteuriser, depending on the design; a date codes on the bases of the
single tunnel for a single deck, or a double tunnel for a double deck. For the purpose of cans, as well as potentially
this section, a one/two tunnel pasteuriser will be referred to. damp packs.
A pasteuriser is normally constructed of stainless steel and has a series of water tanks beneath the lower tunnel.

BEVERAGE CAN
Europe and Asia
PASTEURISATION
WATER TANKS:
Depending on the make/model/design of the pasteuriser, this will determine the number of water tanks required.
Usually, they have eight, nine, or ten tanks. For the purpose of this section, a ten-tank pasteuriser will be referred to. The
ten water tanks also relate to the ten zones of the pasteuriser.
The pH of the pasteuriser water is very important, as alkalinity can cause staining of the Cans and Ends, also softening
and peeling of the can decoration could occur. Ideally the pH should be maintained between 6.5 and 7.5.
SPRAY BARS:
At the top of each tunnel, there are a series of stainless steel spray bars, which spray circulated water of variable
temperatures and pressures, depending on which zones they are spraying. The water is pumped from the individual
water tanks through spray bars on to the filled Cans.
Beneath the spray bars, there are normally perforated stainless steel plates which have raised holes that minimise
clogging and facilitate the cascade – like spraying of the Cans with large amounts of water in such a way that all of the
Cans that are passing beneath them receive an equal amount of treatment.

BEVERAGE CAN
Europe and Asia
PASTEURISATION
PASTEURISER CONVEYORS:
Cans of filled product are transferred through the processing area of the pasteurising tunnel either on flat bed plastic
belts or steel belt systems, or on earlier models, a walking beam conveyor system.
The whole conveying system is placed above the water tanks and below the water spray bars.
The perforated plates below the spray bars are located above the conveyor system.
On modern pasteurisers, there is a control chart or graph showing a continuous display of running temperatures in the
various zones. The functions of these zones are as follows.
HEATING ZONES 1 – 3
Temperatures are increased in stages through these zones as Cans pass through the pasteuriser, until they reach the
superheat zone.

BEVERAGE CAN
Europe and Asia
PASTEURISATION
SUPERHEAT, ZONE 4
The Cans in the superheat zone are exposed to a temperature slightly higher than the pasteurisation zones (5 & 6), to
enable the centre of the beverage in the Cans to reach the pasteurisation temperature, within a reasonable amount of time.
PASTEURISATION ZONE, 5 AND 6

These are the actual pasteurisation zones. The temperature of the beverage contained in the Cans is maintained at a
defined level for a specified period of time. Both of these parameters determine the number of pasteurisation units (PUs) to
ensure optimum product quality and preservation.
RE-COOLING ZONES 7 – 10
The temperature of the Cans decrease as they pass through each of the re-cooling zones; The Cans should leave the
pasteuriser at the ambient temperature or slightly above.
The average time it takes for Cans to pass through the pasteuriser without stopping is 45 minutes.
CHEMICAL DOSING OF PASTEURISERS:

There are usually two types of chemicals added to the pasteuriser water; these are as follows:

BEVERAGE CAN
Europe and Asia
PASTEURISATION
BIOCIDE
This is a disinfectant chemical and is used in the warm up and cooling tank zones(1,2,3 & 7,8,9,10), The main purpose of
this chemical is to eliminate microbiological growth and diseases such as Legionella. Due to the high temperatures reached
in the superheat and pasteurising zones(4,5 & 6), there is no need to dose them.
Overdosing of this chemical could lead to corrosion of the Cans, tab staining on the Ends and possibly accelerate stress
corrosion cracking of the Can ends. Certain parts of the pasteuriser would also suffer with corrosion.
Under dosing could lead to bug growth, slime build up and blocked spray bar nozzles, resulting in poor pasteurisation
performance on the product.
INHIBITOR
The main purpose of this chemical is to prevent corrosion of the Cans and ends as well as the pasteuriser itself. This chemical
is normally fed into the main water supply to the pasteuriser, therefore the inhibitor is present in all ten tanks/zones.
Overdosing of this chemical has no real adverse effect other than the cost of the process.

BEVERAGE CAN
Europe and Asia
PASTEURISATION Note: All chemicals used in

customers pasteurisers must be
Under dosing of inhibitor can lead to dome staining of the Cans, tab staining of the compatible with the coatings,
ends and also corrosion of some pasteuriser machine parts. inks and lacquers that are used
on the finished Can and end.
Both these chemicals are normally added using an automatic dosing system and have
to be closely monitored by the customer. These systems are generally excellent, but it is For clarification of this, please
seek the advice of your local
not uncommon for the feeder tank of chemical to run out, or the dosing pump to fail. If
Rexam CTS Engineer.
these conditions remain undetected it can lead to Can issues such as dome
staining/rusting or tab staining on the end. It is important that procedures/controls are
implemented to ensure that this does not occur.
PASTEURISATION TEMPERATURE:
The customer must strictly control the pasteurisation temperature. Failure to do so will result in out of specification PU’s
(Pasteuriser Units) and therefore potentially poor product quality. Issues with the Cans and ends could also occur.

BEVERAGE CAN
Europe and Asia
PASTEURISATION
During the pasteurisation of Cans, the factors creating internal pressures have to be considered in order not to exceed the
dome reversal strength of the Cans or reach the peaking pressure of the Ends.
The major factors contributing to pressure inside the Cans are:
1. Filling temperature.
2. Fill volume/headspace.
3. Air in the headspace.
4. Level of carbonation.
5. Excessive exposure to temperature.
See also Liquid Nitrogen Dosing
Special charts apply for the calculation of expected internal pressure and help can be obtained from our CTS
Representatives. The charts are made up of ordinary C02 holding products. If liquid nitrogen or other gasses are used,
there are other means of calculation.

BEVERAGE CAN
Europe and Asia
PASTEURISATION
Typical problems that can occur with the Cans and ends if the pasteuriser temperature is
too high are:- Note: It is also worth noting
that all the four problems with
cans and ends that are
1. Dome Growth (Cans) mentioned in this section could
2. Dome Reversal (Cans) occur if the fill volume/Nitrogen
3. Tab Over Seam (Ends) dosing/carbonation of the cans
4. Peakers (Ends) are too high.
If there are problems resulting in Cans being delayed in the pasteuriser for several minutes
or hours, it is possible that the above problems will occur if the process is not controlled.
Pasteurisers are normally equipped with a "Quench" system, so that when Cans are delayed in the pasteuriser, cool water
is administered to the super heat and pasteurisation zones to automatically control the temperature within specified limits.
Some pasteuriser conveyors stop when the filler stops, therefore filled Cans are held up for extended periods in the
pasteuriser. This could also result in the above problems occurring.

BEVERAGE CAN
Europe and Asia
PASTEURISATION
Rexam has a Pasteurisation control logger which measures the pasteurisation process and gives the user valuable
information regarding the customer’s filling/pasteurisation conditions.
The logger transducer fits inside the Can, which is then filled and seamed, placed in a special container and then
passed through the pasteuriser. On exit from the pasteuriser, the logger is removed from the Can and the Data is
downloaded giving accurate recordings achieved on the internal pressure, temperature and pasteuriser units (PU’s).

BEVERAGE CAN
Europe and Asia
PASTEURISATION
GENERAL MAINTENANCE AND SANITATION

The water in the can warmer/pasteuriser needs to be kept clean and changed at regular intervals, to avoid build up of
corrosive salts and sludges. This should be incorporated along with a pasteuriser water treatment programme,
incorporating biocides and inhibitors.
Due to the development of water efficient pasteurisers with advanced heat exchange systems, the above is even more
important, or there could be a relatively sharp increase in chemical instability, leading to problems with the overall
appearance of the filled cans.
If the above is incorporated as part of an overall pasteuriser maintenance programme, it will also minimise the risk of
spray bar nozzle blockages, thus giving more consistent product quality and maintain the attractive appearance
of the Can.

BEVERAGE CAN
Europe and Asia
FILLED CAN HANDLING
RINSING AND DRYING PRIOR TO PACKING

Cans and Ends should be rinsed with low salt or deionised water after the can warmer/pasteuriser, but without
significant cooling off and must remain above the dew point temperature.
The rinser should be interlocked with the through conveyor, so that cans cannot be run without the rinse being
operational. An efficient dryer (air knives or nozzles) must be used to minimise the water left on the can and end, and
should be interlocked to the conveyor, preventing cans running through without the dryer being operational. The whole
can and the end, in particular, need to be visually dry due to the risk of score stress corrosion. Please see the paragraph
"Stress Corrosion" for details.
Changes in secondary packaging can have an influence on the level of moisture retained in a pack, especially on
moving from carton to plastic film. Shrinkfilmed trays are prone to entrap moisture and need to be ventilated at both
ends by applying the film as a banderol. Perforated film is also recommended.
Any board used in trays or boxes should comply with acceptable specifications for chloride and sulphate, commonly
max 0.05% calculated as NaCl and 0.2% as Na2SO4.

BEVERAGE CAN
Europe and Asia
FILLED CAN STORAGE
LOADING AND WAREHOUSING

Filled cans should be stored upright.
Remove any damaged cans or trays prior to loading.
Ensure that the pallets used for filled goods are suitable for weight of the packs, undamaged and without any protruding nails.
International standards applicable to the chemical and moisture content of pallets and other packing materials must be
adhered to.
Stack trays such that each is fully supported and does not overhang the pallet. A binding formation reduces the risk of can
abrasion.
Ensure that trials are carried out if new secondary packaging is introduced, as it may effect the stability.
Ensure that pallets are stacked squarely on top of each other to avoid uneven load.

BEVERAGE CAN
Europe and Asia
FILLED CAN STORAGE
Examine the design of fork lifts to ensure that they do not cause damage to the filled goods.
Fork lift drivers must be trained and alerted to the importance of careful can handling.
Filled product should not be stored at temperatures exceeding 37°C or below 0°C. Filled stock should not be exposed to
direct sunlight.
Shelf life expectancy of Cans may be significantly reduced at elevated temperatures.
Can bases and ends may distort if stored at too high a temperature.
Filled stock pallets should be stored in such a manner, which allows easy access for regular examination for leaking packs.
Any wet package must be removed when identified.
Ensure good air circulation and that good stock rotation is in place (First In First Out).

BEVERAGE CAN
Europe and Asia
TRANSPORT
All goods should be carefully inspected before loading and if any wet or damaged packs are found, they should be
removed immediately.
Vehicles or containers used for transportation must be free from insects and dust, with no residues of extraneous
materials/odours present from previous products shipped in them.
Under no circumstances should a vehicle have external damage which may result in water seepage, or have internal
damage which can cause harm to the load.
Loading must be conducted in such a manner as to avoid the Cans being subjected to hydraulic shock which could
cause the panel of the end to blow, or the Can bases to reverse.
Never stack filled pallets on top of each other at transportation, or place other goods on top which can cause
damage to the packs. The supply chain should be monitored on an on going basis and suitable training given to the
people involved in transportation, storage and retail.

BEVERAGE CAN
Europe and Asia
TRANSPORT
LONG DISTANCE DISTRIBUTION AND ADVERSE CLIMATIC CONDITIONS

Special precautions are needed for long distance distribution, particularly through tropical areas.
In spite of originally dry packages, climatic conditions with large temperature variations may form condensation and
therefore shrink filmed trays are not the ideal packaging method.
A wrap around multi pack gives the best natural ventilation and, because it is cardboard, this gives a further advantage
with some moisture being absorbed. This type of pack gives better overall protection than plastic film.
Multipacks, holding the Cans firmly together are not ideal either, as abrasion could take place along a Can-to-Can
contact line and leakage could occur after long exposure to transport movements.
Loose Cans in a wrap around box allows the Cans to slightly rotate and thus reduce the wear.
The vehicle or container, should be loaded in such a way as to avoid movements within the load. Inflatable air bags
around the inside wall of the vehicle or container are advised, to take up any free space.

BEVERAGE CAN
Europe and Asia
TRANSPORT

Never use empty pallets or similar to fill spaces in containers, as the sharp edges might puncture the Cans.
All packing material must be dry.
Where goods are to be transported from cold to warm climates, the moisture content of all packing material must be
monitored and controlled to avoid "cargo sweat", this is a potential risk particularly in container transportation. To avoid
high humidity developing in containers any wood used in pallet manufacture should not exceed 20% moisture content. This
figure also applies for any wooden container floor and kiln dried wood is recommended for the manufacture of pallets.
Silica gel bags, or similar, will assist by absorbing a level of humidity.
Temperature within the containers is controllable, to some extent, by the use of either forced or naturally ventilated container
units. Insulated containers will reduce the temperature changes of the container content as the ambient temperature rises
and falls throughout the 24 hour cycle.

BEVERAGE CAN
Europe and Asia
TRANSPORT

Should humidity occur it can cause the following problems with filled stock.
1. Rusting of bases on steel cans .

2. Stress Corrosion on end scores.
3. Oxidation/staining of end tabs.
4. Damp/wet secondary packaging.
5. Mould on filled packaging.
Owing to the thermal conductivity of steel, temperatures inside containers will exceed that of surrounding ambient air
by up to 20 degrees when stored in direct sunlight. Temperatures will also vary between the centre and outer edge
of the container load.
Storage of containers loaded with Cans in the open air should be avoided.
Filled Can packages and pallets should be removed as soon as possible from transport containers upon arrival at
their final destination and be warehoused or distributed accordingly.

BEVERAGE CAN
Europe and Asia
PRIMARY AND SECONDARY CORROSION
PRIMARY LEAKERS AND SECONDARY CORROSION

Primary leakage can come from a manufacturing fault, filling fault, or a Can handling fault (e.g. fork truck damage etc).
Primary leakage, if not removed, leads to secondary corrosion.
High salts in carton trays can accelerate corrosion.
Cases containing leaking Cans must be removed from the pallet as soon as they are detected.
Never put Cans from a leaking case back into good stock, as corrosion will have already started and these will
contaminate other good Cans, causing further secondary corrosion.
Good rotation of stock will help identify any issues and will help reduce the spread of leakage.
Yellow metals (brass, copper etc.) must not be used on Can filling lines, as fragments can get embedded in the riding
edge and accelerate corrosion.

BEVERAGE CAN
Europe and Asia
PRIMARY AND SECONDARY CORROSION
Secondary corrosion normally occurs on the base of the Cans on the riding edge or chime; however on occasions, it
can also occur on the side wall or the can body.
One leaking Can could result in one or two leaking trays, but if left, can result in a whole or
several pallets being destroyed.

BEVERAGE CAN
Europe and Asia
STRESS CORROSION
The information that follows is a way of helping you understand this issue and take action to keep it under control.
By careful control and vigilance, this problem can be avoided or minimised. Ongoing checks should be carried out to
quantify the level of residual moisture remaining on the end immediately after the dryer (see BCME).
WHAT IS TRANS-GRANULAR STRESS CORROSION?

Aluminium alloys are susceptible to water induced Hydrogen corrosion which may take the form of trans-granular
cracking. Cracks initiate at multiple points in the base of the score area on the exterior panel of an aluminium Easy Open
End and propagate towards the interior face of the End in a fan-like cleavage pattern.
When the cross-sectional area of the remaining score residual is reduced to a level that the stress exceeds the strength of
the alloy, the final portion fails by ductile overload and the pour panel blows open.
These failures typically occur in storage warehouses or during transportation in the hot, humid period of the year, and
can occur as early as 1 week after filling.

BEVERAGE CAN
Europe and Asia
STRESS CORROSION
WHAT IS THE CAUSE?

Water in the presence of oxygen is corrosive to unprotected aluminium (the score area).
The rate of corrosion is accelerated by salts or other corrosive materials naturally contained within, or added, to the
water.
The shape of the score, determined by the wear of the scoring tool is not an important factor, nor is the rolling direction
of the metal.
WHAT ARE THE CONDITIONS WHICH MUST BE PRESENT?

The material must be susceptible to stress corrosion.
Aluminium : The alloy used in the manufacture of Easy Open Ends has unique properties of strength and formability.

BEVERAGE CAN
Europe and Asia
STRESS CORROSION
Stress : Applied tensile stress on the score is increased when the internal pressure from the product in the Can increases.
Both high carbonation and high temperature will increase the stress.
ALUMINIUM
There must be an "ENVIRONMENT" which is conducive to causing corrosion. A1 A1
STRESS
CORROSION
Environment : Wet scores are conducive to corrosion. CRACKING H+
WATER (H20)
High temperatures accelerate the corrosion and high humidity retards the
drying process. PRESSURE
TEMPERATURE
Contaminated rinse water such as with track lubricant may accelerate the corrosion.
EASY OPEN ENDS WILL NOT FAIL FROM STRESS ACCELERATED CORROSION CRACKING IN THE ABSENCE
OF AN EXTERNAL ENVIRONMENTAL CAUSE, EVEN THOUGH SUBJECT TO A HIGH DEGREE OF STRESS.

BEVERAGE CAN
Europe and Asia
STRESS CORROSION
RECOMMENDATIONS:
The most effective and efficient way to prevent stress corrosion of Easy Open Ends, is to rinse the Can/End and dry well
before packing.
Keep dry and provide correct conditions for filled Can storage and distribution.
Further details are available as a technical bulletin issued by Beverage Can Makers Europe, which is also included as
part of this manual.
STRESS ACCELERATED CORROSION CRACKING IS PREVENTABLE

BEVERAGE CAN
Europe and Asia
TAB AND DOME STAINING
Staining on the dome area of aluminium Cans and the unlacquered surface of stay on tab (SOT)
end, refers to the visual, even discolouration of the aluminium, ranging from a light golden colour to
a dark brown or black stain.
This is generally observed immediately after pasteurisation, if the pasteuriser water is not under
control. It may also appear over time after filling as a result of the presence of moisture in the pack.
Stained tab
Dome and tab staining are caused by iron oxides and manganese oxides which accumulate on the
unconverted or unlacquered surface of the aluminium. The source of the iron and manganese is the exposed area of the
aluminium Can and aluminium end.
During pasteurisation the Can is exposed to high temperature water, at times containing chemical additives eg biocides,
anti-corrosion additives etc. Under certain conditions the aluminium and aluminium oxide from the exposed areas of the
Can and end dissolve rapidly, exposing large amounts of iron and manganese to the pasteuriser water. Unchecked, these
metals may easily oxidise (corrode) to form metal oxides resulting in dome and/or tab staining.

BEVERAGE CAN
Europe and Asia
TAB AND DOME STAINING
This condition will be compounded by packing a wet Can/end into shrink wrapping.
Filled cans leaving the pasteuriser with dome and/or tab staining is a clear indication that the pasteuriser water/chemical
balance is not in control and that, already, conditions leading to possible causes of stress corrosion of the score line of
the pour panel of the Easy Open End are present, which may result in blown scores.
In order to prevent dome and/or tab staining it is recommended that your pasteuriser or Can warmer be treated by a
specialist water treatment company.
The pasteuriser water should be controlled at a neutral pH of 6.5 to 7.5. Avoid spillage or carry over of chemicals in the
process which would raise the pH. Closely monitor and control the addition of biocides and avoid those containing
chlorine. Select a total water treatment programme that provides protection over the pH range.
Ensure that your pasteuriser water contains sufficient treatment chemicals at all times to control:
• pH.
• Algae.
• Corrosion of cans and ends, as well as pasteuriser parts.

BEVERAGE CAN
Europe and Asia
DOUBLE SEAM SPECIFICATIONS
Double Seam Terminology .... > 57mm(206) Setup Specifications .... >
50mm(200) Setup Specifications ... > 57mm(206) Operation Specifications .... >
50mm(200) Operation Specifications .... >
52mm(202) Setup Specifications .... >
52mm(202) Operation Specifications .... >

BEVERAGE CAN
Europe and Asia
DOUBLE SEAM TERMINOLOGY

SEAM THICKNESS
FINISHED DOUBLE SEAM
SEAM GAP
COUNTERSINK
DEPTH
COMPOUND
CAN
END
BODY
OVERLAP HOOK
SEAM
LENGTH
END
HOOK

BEVERAGE CAN
Europe and Asia
50mm (200) DOUBLE SEAM SPECIFICATION FOR BEER & BEVERAGE CANS
SET UP SPECIFICATIONS AND PROCEDURES
Seamer Pin Height Settings : Pin Height = (Nominal Can Height - 7.70) +/- 0.25mm
1ST OPERATION SET UP 2ND OPERATION SET UP

PARAMETERS SETUP SPECIFICATIONS PARAMETERS SETUP SPECIFICATIONS
1st Operation Finished Can Height Nominal Can Height +/- 0.20mm 2nd Operation Countersink Depth 6.60mm +/- 0.10mm
1st Operation Countersink Depth 6.60mm +/- 0.10mm 2nd Operation Seam Length 2.55mm +/- 0.10mm
1st Operation Seam Length 1.95mm +/- 0.05mm 2nd Operation Seam Thickness As Per Matrix Target +/- 0.03mm
1st Operation Seam Thickness 2.05mm +/- 0.05mm 2nd Operation Body Hook Length 1.60mm +/- 0.10mm
End Hook Length 1.60mm +/- 0.10mm
Actual Overlap 0.90mm Minimum
Body Hook Butting 72% to 92% Aluminium Cans
Seam Gap (Directly After Seaming) Target (For Set Up Purposes) <0.05mm
Optical Only
End Hook Tightness Rating 100% Wrinkle Free
FreeSpace 0.13mm +/- 0.03mm
In the event of any tooling changes or other machinery disruptions, a full set up seam check should be carried out. At this set up stage, at least
2 Cans from each Seaming Head are to be measured on all Parameters.
The Quality Of The Double Seam Is The Responsibility Of The Filler

BEVERAGE CAN
Europe and Asia
OPERATION SPECIFICATIONS
1ST OPERATION SPECIFICATION 2ND OPERATION SPECIFICATION
1st Operation Seam Thickness 2.05mm +/- 0.10mm 2nd Operation Countersink Depth 6.60mm +/- 0.15mm
1st Operation Seam Length 1.95mm +/- 0.05mm 2nd Operation Seam Length 2.55+/- 0.10mm
1st Operation Countersink Depth 6.70mm Maximum 2nd Operation Seam Thickness As Per Matrix +/- 0.05mm
Finished Seam Body Wall Impression
Should Be Visible & Continuous
Body Hook Length 1.60mm +/- 0.20mm
Body Hook Butting 72% to 97% Aluminium Cans
Seam Gap (Directly After Seaming) 0.1mm Maximum (Aim For 0.05mm)
Optical Only
Free Space 0.13mm +/- 0.05mm
Finished Can Height Nominal Can Height +/- 0.04mm
Should any setting adjustment be required, refer to set up specifications and procedures sheet

BEVERAGE CAN
Europe and Asia
Body Hook Butting 72% to 92% Steel Cans
72% to 97% Aluminium Cans
Seam Gap (Directly After Seaming) Target (For Set Up Purposes) <0.05
Optical Only

BEVERAGE CAN
Europe and Asia
1st Operation Countersink Depth 6.92mm Maximum 2nd Operation Seam Thickness As Per Matrix +/- 0.05mm
Optical Only

BEVERAGE CAN
Europe and Asia
Seam Gap (Directly After Seaming) Target (For Set Up Purposes) <0.05
Optical Only

BEVERAGE CAN
Europe and Asia
1st Operation Countersink Depth 6.36mm +/- 0.15mm Maximum 2nd Operation Seam Thickness As Per Matrix +/- 0.05mm
Optical Only

BEVERAGE CAN
Europe and Asia
SPECIAL PACKING TECHNIQUES
Embossed Cans .... >
Liquid Nitrogen Applications .... >

BEVERAGE CAN
Europe and Asia
EMBOSSED CANS
Embossing adds visual appeal and tactility to the Can and is an additional mechanical forming operation to the Can
sidewall, which can be applied for certain designs.
For the best visual effect, it is important that the areas of the can label to be embossed and the embossing features are
developed together.
The specification of the embossing needs to be agreed between the customer and Rexam, as each design will reduce the
axial load resistance of the can and could therefore affect the filling and seaming performance.
A pilot unit is used first to verify the performance before full tooling is ordered.
A high speed, in-line embossing machine is used to produce the commercial Cans.
For further information, please contact your CTS representative.

BEVERAGE CAN
Europe and Asia
LIQUID NITROGEN DOSING OF BEVERAGE CAN PRODUCTS

This section is to briefly explain the use of Liquid Nitrogen Dosing in beverage Cans and its applications.
APPLICATIONS:
1. To give increased pressure to non–carbonated Canned products, enabling the Cans to be handled on the filling line
and in the supply chain, without Can side wall collapse. Examples of products which could require liquid nitrogen
dosing are as follows:
Fruit juices, Smooth beer, Milk, Tea and Water.
2. To stimulate the foam or head formed on Canned Beer, as presented to the customer from a manual or electric pump
in a bar. This is used on beer cans which contain a widget.

BEVERAGE CAN
Europe and Asia

When liquid nitrogen is introduced in to a non–carbonated product, it evaporates to gas and sufficient inert Nitrogen gas
is trapped in the head–space of the Can. This will increase the stability and shelf life of the product due to the reduction
of Oxygen in the filled Can.
When liquid nitrogen is used to stimulate the foam on Canned Beer, it is normally done in conjunction with a widget
which upon opening the Can, releases the inert nitrogen in to a gas which passes through the Beer. The introduction of
Nitrogen in to the Beer by the widget partially substitutes for Carbon Dioxide and gives an extra stimulus for foam to be
formed as the Beer is poured from the Can.
RECOMMENDATION:
It is recommended that the absolute minimum internal Can pressure required for the safe handling and storage of all
beverage Canned products should be 1.5 bar.
In most cases internal Can pressures are measured automatically by equipment that is located just prior to the packaging
of the cans. It measures the end panel deflection on each can, automatically rejecting cans with a low/high deflection,
which is an indication of the internal Can pressure being achieved.

BEVERAGE CAN
Europe and Asia
BRIEF DESCRIPTION OF THE DOSING UNIT:

The dosing units differ according to the manufacturer. There are units which can vary the amount of Liquid Nitrogen
deposited into the Cans, depending on the speed of the Can filler. The flow rate automatically reduces when the filler is
running at slow speed, and then automatically increases as the filler speed increases.
Some older designs of equipment uses an interchangeable nozzle system of a calculated size, to yield the correct
amount of Liquid Nitrogen for the individual product(s).
For the purpose of this section, an automatic dosing system will be referred to.
The Liquid Nitrogen dosing unit consists of a control cabinet and dispenser unit, which produces a continuous stream of
Liquid Nitrogen, the flow of which is varied according to the speed of the Cans that pass beneath it.
The dispenser/doser is positioned in an inert gas tunnel above the filler/seamer transfer, being positioned as close as
possible to the end of the gas tunnel prior to the seamer. Positioned here, Oxygen is prevented from condensing into the
stream of Liquid Nitrogen and, to some extent, assists in removing air from the head space in the Cans prior to them
being seamed.

BEVERAGE CAN
Europe and Asia
TYPICAL PROBLEMS:
Typical problems that can occur with Liquid Nitrogen Dosing are as follows:
1. Dosing failure will result in flat product within the Cans.

2. Low dosing/dosing failure could lead to low internal pressure in the Cans and also, low side wall strength. This could
lead to problems with handling and storage as Cans with a weak side wall could collapse during stacking/storage.
3. Over dosing could result in excessive dome growth on Cans prior to/or after pasteurisation.
4. Over dosing could also cause dome reversal during pasteurisation.
5. Over dosing could also cause end peakers.
It is very important that the Liquid Nitrogen Dosing unit is set up correctly, prior to production runs. Failure to do so will
result in high spoilage issues due to under/over dosing. It is not uncommon for the units to be overdosing prior to
pasteurisation and dome growth on the Cans to be in excess of 2mm. These Cans can cause jams in the twists on the
seamer discharge and, when the Cans are pasteurised, the problem of excessive dome growth will increase, creating
major problems with twists and packaging machines.

BEVERAGE CAN
Europe and Asia
Over pressurised cans could also be a problem if they reach the market place. The internal pressure in these Cans will be
much higher than recommended and could be the cause of several consumer complaints regarding exploding Cans.
The customer must also control the correct fill volume of product in the Cans. If Cans are overfilled, the headspace is
reduced, therefore there will be a greater internal pressure within the Cans, particularly after Liquid Nitrogen Dosing. This
could also result in problems 3, 4 and 5 occurring.
Rexam has an In Can Pressure Logger which measures the internal pressure of filled Cans during pasteurisation. This
equipment has been of great value in the past when evaluating in Can pressures on Liquid Nitrogen Dosed Cans.
See your local CTS engineer for details.

BEVERAGE CAN
Europe and Asia
CUSTOMER SERVICES
Handling and Seaming of Beverage Cans .... >
Seamer Maintenance .... >
Line Efficiency Studies .... >

BEVERAGE CAN
Europe and Asia
HANDLING AND SEAMING OF BEVERAGE CANS

A two day theoretical and practical training course
DAY 1 – CAN AND END MAKING, FILLING OPERATIONS AND TRANSPORT
• Introduction and presentation of the delegates • Handling of filled cans

Plant tour (dependent on site) – secondary packages
– single packs, multi packs, shrink film and boxes.
• Can and End making technology – pallet loading
– can abrasion
• Specifications and quality criteria
• Storage conditions and transportation
• Handling of empty cans - temperature, relative moisture and routines for inspection
Return of packing materials - tropical environment
• The filling and seaming of beverage cans • Corrosion

Filling principles and the importance of air removal
Pasteurisation and Water Treatment

BEVERAGE CAN
Europe and Asia
HANDLING AND SEAMING OF BEVERAGE CANS

DAY 2 – SEAMING AND SEAM CONTROL
• Seamers and seaming theory

– the basic machine functions
– the seaming chucks and the seaming rolls
– the double seam
• Seam specifications
• Measuring technique – set up and operational targets and tolerances
– manual equipment
– computerised equipment • Practical seam measurements
– non destructive equipment
• Seam evaluation
• Practical training at seamer set up and adjustments – some basic statistics
– preparation of samples for seam control – from readings to adjustments

BEVERAGE CAN
Europe and Asia
SEAMER MAINTENANCE
In certain countries, Rexam are able to offer a complete Seamer Maintenance package using fully trained Rexam
employed engineers.
Should you wish to utilise this chargeable service please call your CTS representative.

BEVERAGE CAN
Europe and Asia
LINE EFFICIENCY STUDIES

Rexam are keen to encourage all customers to fill cans as efficiently as possible. For that reason Rexam are able to offer
a service that specifically studies the filling line to identify areas of the line that could be improved.
THE OBSERVATION AREAS INCLUDE:
Area 1 Depalletiser, Empty Can Conveyors, Single Filer and Rinser
Area 2 Filler, End Feed and Seamer
Area 3 Filled Can Conveyors, Single Filers, Multi-pack Machines, Tray Packer and Wrap-around Packer System
Area 4 Palletiser, Pallet Magazines, Stretch Wrapper and Pallets produced
Should you wish to take up this chargeable service, please contact your CTS representative.

BEVERAGE CAN
Europe and Asia
APPENDIX
BCME Document .... >

Stress Corrosion-Technical Bulletin
The recommendations below have been formulated to minimise the risk of stress corrosion on
aluminium easy open ends used in the packaging of beverages in aluminium and steel 2 piece
beverage cans.
Background
Under normal conditions of use, aluminium alloy beer and beverage Ends perform without any
issues however, under certain filling and storage conditions external corrosion takes place in the
score area of the End that causes premature opening of the score panel.
The cause of this failure is commonly referred to as stress corrosion, but is otherwise known as
(TGSC) Trans-granular Stress Corrosion.
Stress corrosion typically takes place in products packed in shrink-wrap packaging during storage in
warehouses, but can also occur in non shrink-wrapped packages. The risk of stress corrosion rises
dramatically in hot and humid climates typically +30deg. C and humidity +60% relative humidity
(rh). Depending upon conditions, described later, failure can occur in a matter of days or take
several months.
Visible tab staining can be an indicator to the presence of stress corrosion even though the corrosion
mechanism may not yet have developed to the point where the score panel has opened.
For the better understanding of stress corrosion, please refer to attached detail at the end of this
bulletin.
Cause and Result
The corrosion takes place in the score area of the End due to the presence of moisture and the
resultant chemical reaction with the aluminium alloy. The ongoing corrosion occurs at the base of
the score, weakening the residual metal. This corrosive weakening together with the internal Can
pressure and the inherent stress created within the End during manufacture, causes the premature
opening of the score panel. The corrosion process is greatly accelerated by the increased presence of
salts (chlorides and sulphates / halides) which can remain on the End or be present in any residual
rinse water after inadequate drying of the Can body and End.
Failure of one can in a shrink-wrapped pack will normally release moisture and consequently initiate
corrosion in the remaining cans within the pack.
Recommendations
The BCME strongly recommend that the following precautions be taken to minimise the risk of
stress corrosion:
1. Post Seamer Rinsing
The Can and End should be thoroughly rinsed after seaming to remove any product or process
residues. The rinse water supply should ideally be electrically interlocked to the Seamer such that the
line cannot run without rinse water sprays being operational.
Note: Conveyor/Track lubricant (soap) and/or product carryover to the warmer water can contribute
to corrosion. Build up of these contaminants in the water can be prevented by efficient rinsing prior
to entry.
2. Can Warmer/Pasteuriser
The use of a can warmer/pasteuriser is recommended to ensure that the product temperature at the
time of secondary packaging is above the dew point. This will help prevent condensation from
forming on the Cans and Ends during subsequent warehousing. The presence of salts such as
Chlorates and Sulphates accelerate the stress corrosion process therefore management and analysis
of the water quality in this area is essential.
3. Can & End Rinsing
Regardless of whether the filled Can has been through a can warmer/pasteuriser both the Can body
and End must be thoroughly rinsed prior to secondary packaging to remove any salts, track lubricant
etc.
This should ideally take place as near as possible to the secondary packaging station but immediately
prior to the Can & End drying station.
• The Cans and Ends should always be rinsed in single file.
• It is recommended that the rinsing takes place on the final can twist prior to the drying station
via fan type nozzles ensuring that no contaminants remain on the Can or End.
• The rinser sprays should ideally be electrically interlocked to the can conveyor control such that
if the rinser is not operational the conveyor will not run.
• If it is necessary to use track lubricants these should have low chloride/sulphate levels and be
minimally applied at all times.
• The concentration level of track lubricant should be minimised and controlled on an ongoing
basis plus ideally interlocked with line controls to prevent excessive foaming.
• All evidence of track lubricant on the Can/End must be removed at the final rinse station.
• The rinse water ideally should have a pH between 6 and 8.0.
• Chloride levels should be <10p.p.m and Sulphates and Nitrates<15p.p.m.
• Where water treatment is required water softening by reverse osmosis is the preferred option.
• Regular checks on water quality should be maintained at this critical application point.
4. Can & End Drying
The objective is to achieve zero residual moisture on the Can and End after the drying operation and
prior to secondary packaging. This applies in particular to the End and most importantly its score
area.
Score Corrosion does not occur on dry Ends.
• The Cans and Ends should always be dried in single file. This is more effective than mass
drying.
• The dryer should be electrically interlocked to the can conveyor control such that if the dryer is
not operational the conveyor will not run.
• It is strongly recommended that the efficiency of dryers is checked routinely (see: test Method
for Assessing the Dryness of Can Ends).
• It is also recommended that the dryer is subject to an effective maintenance programme to
maintain its optimum performance.
• The BCME consider that Can and End drying is a critical element of the beverage filling
operation.
• The responsibility for adequate Can and End drying rests with the filler.
5. Secondary Packaging
Existing and future secondary packaging developments must be reviewed in conjunction with any
additional actions required at the filling plants to minimise the risk of stress corrosion.
• Perforated shrink film will help any moisture to evaporate as will ‘vent’ holes at the end of each
pack.
• The use of board packaging will help absorb retained moisture further minimising the risk of
stress corrosion.
• The use of plastic packaging without any cardboard will increase the risk of stress corrosion.
6. Storage
Pallets of filled product should be stored in a manner that allows good air circulation and ease of
inspection. Filled product should be inspected on a regular basis and any pallets showing evidence
of leakage should be removed immediately. As far as is possible, temperature variations within the
warehouse should be avoided.
7. Treatment of filled Product affected by Stress Corrosion.
All packs containing any End (single or multiple quantities) with blown score panels should be
removed and the entire pack scrapped, along with any other affected stock.
Do not attempt to salvage any wet cans as it is a recognised fact that these cans, due to product
contamination leading to secondary corrosion, have a high risk themselves of leaking at a
future date.
8. Transportation of filled Product.
Pallets should be transported such that there is adequate ventilation and room for air circulation.
Use of block stacking in containers is not recommended.
The foregoing guidelines are intended to help minimise the risk of secondary corrosion
occurring. For further help and guidance please contact your BCME members Customer
Technical Service Department.
Test Method for Assessing the Dryness of Can Ends
1. Equipment required:
1. A balance that is accurate and repeatable to at least 0.001g.

2. Air tight containers and swabs.
Either a. Sterilin tubes and cotton wool buds
or b. Sealable polythene bags and filter papers
2. Test Procedure:
1. Weigh swabs in the sealed containers to an accuracy of 0.001g. Record the weights.
2. Take samples from the line directly after the dryers and swab immediately.
3. Carefully use the swab to remove all residual water from each individual End, including under
the tab and in the countersink and score.
4. Reseal the swab into the container.
5. Reweigh container and swab. Record the weights.
6. The difference in weight is taken as the amount of moisture remaining on the End.
3. Test Frequency
Recommended daily, but should be continually reviewed depending on consistency of results and
process capability.
4. Points to note:
1. The time between sampling and testing should be kept to a minimum.

2. If drying in single lane take 4 samples from each lane.
3. If drying in bulk take 4 samples evenly across the belt.
4. Prevention of contamination of the items to be weighed is important to avoid spurious results.
5. The swabs should be out of containers for the minimum time between taking weights to prevent
moisture pick up / loss.
5. Standard to be achieved:
The objective is to achieve zero residual moisture on the Ends but the following is an achievable
minimum practical operating standard based on available modern equipment.
It is recommended that this specification is used when purchasing new drying equipment.
Recommended Operating Standard Action
Target average less than 3mg per End
Single End 9mg or greater Establish cause & rectify.

Recheck to ensure standard is achieved
4 can average 7 mg or greater per End Establish cause & rectify.
Recheck to ensure standard is achieved
Visual checks should be carried out on an ongoing basis to verify drying performance is maintained.
Description of figures
Fig.1 Configuration of Stay-on-Tab Easy-open-End and Score
Fig.2 Environmental Stress Crack development in Aluminium End Score
Fig 3 Environmental Stress Cracking: Fracture Surface of Aluminium End Score.
Fig.4 Fracture of Aluminium End Score showing fatigue effects.
Fig 5. Fracture of Aluminium End Score physically induced by pressurising to bursting strength.
Fig 6. Tab staining on Ends affected by Stress Corrosion.
Fig.1: Typical configuration of Stay-on-Tab Easy-Open-End and Score
B B
Figure 1a Figure 1b
EO End Exterior Plan View Scored Region
Material Thickness Score Residual Thickness
Section B - B
Figure 1c Score Section profile
Fig.2: Environmental Stress Crack Development in Aluminium End Score
Score region shown

in Figure 2
Score Residual Thickness
Material Thickness
Environmental stress crack showing typical branching progressing from pit beneath
score exterior. Secondary sites of corrosion and crack development are present at the
left-hand edge of the score. Field of view width ≈ 200µm.
Fig. 3: Environmental Stress Cracking: Fracture Surface of Aluminium End Score
Top of score
residual
Secondary
cracks
Fan shaped
cleavage
cracks
Inside edge of
score residual
Environmental stress cracking: Surface of score residual fracture showing fan shaped
cleavage cracks. Secondary cracks typical of environmental stress cracking are also visible.
Field of view width ≈ 230µm.
Fig. 4: Fracture of Aluminium End Score Showing Fatigue Effects
Top of score
residual
Striations
Inside edge of
score residual
Fracture surface of aluminium end score showing horizontal striations indicating fatigue
effects. Field of view width ≈ 180µm.
Fig. 5: Fracture of Aluminium End Score Physically Induced by Pressurising to Bursting Strength
Top of score
residual
Ductile cups
and cones
visible
Inside edge of
score residual
Fracture surface of unused aluminium end score blown under pressure showing ductile
cup/cone physical failure effects. Field of view width ≈ 190µm.
Fig. 6: Tab staining on Ends affected by Stress Corrosion
Typical unlacquered Tab

FILLER
END FEED GRAVITY RINSER SINGLE FILLER VACUUM TRANSFER MECHANICAL MASS TRANSFER
DEPALLETISER
PASTEURISER
COARSE TWIST CANWARMER
FILL CHECK & RINSE
SEAMER
ACCUMULATION TABLE
AIR BLOWER ELEVATOR

AIR BLOWER FOR FILL CHECK FOR BASE OF CANS PALLETISER PALLET STRETCH WRAPPER
END AND CAN BODY TWIST & END RINSER
CODER
SHRINK TUNNEL
TRAY LOADER
WRAP AROUND
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SEAM GAP
COUNTERSINK
DEPTH
COMPOUND
CAN
END
BODY
OVERLAP HOOK
SEAM
LENGTH
END
HOOK
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BEVERAGE CAN

Europe and Asia

Customer Reference Manual

© Rexam Beverage Can Europe Limited. 2004. All Rights Reserved

Introduction to Rexam .... > Innovation .... >

Our Vision .... > Investment in People .... >

Service .... > The Environmental Approach .... >

Quality .... >

Section 1 – Page 1 Back to index < >

REXAM BEVERAGE CAN EUROPE & ASIA

Section 1 – Page 2 Back to index < >

Section 1 – Page 3 Back to index < >

SERVICE – UNDERSTANDING AND EXCEEDING A CUSTOMER’S EVERY NEED

Section 1 – Page 4 Back to index < >

QUALITY – AT THE HEART OF EVERYTHING WE DO

All of our plants are ISO 9002 accredited.

Section 1 – Page 5 Back to index < >

INNOVATION – IN WHAT WE PRODUCE AND THE WAY WE WORK

Section 1 – Page 6 Back to index < >

INVESTMENT IN PEOPLE – AT THE CENTRE OF REXAM’S BUSINESS PHILOSOPHY

Section 1 – Page 7 Back to index < >

THE ENVIRONMENTAL APPROACH THAT MAKES GOOD BUSINESS SENSE

All of our plants are ISO 14001 accredited.

Section 1 – Page 8 Back to index < >

CONTACTS & LOCATIONS

Where we are .... >

Who we are .... >

Who to contact .... >

Section 2 – Page 1 Back to index < >

Head Office Milton Keynes

Oss Mont Ejpovice

Valdemorillo La Selva Nogara San Martino Manisa Enzesfeld

Section 2 – Page 2 Back to index < >

Section 2 – Page 3 Back to index < >

Rexam Beverage Can Italia Srl

Section 2 – Page 4 Back to index < >

Rexam Beverage Can Italia Srl Rexam Beverage Can Iberica SL

Rexam Beverage Can Naro-Fominsk

Rexam Beverage Can Iberica SL

Section 2 – Page 5 Back to index < >

Rexam Beverage Can Europe Limited

Rexam Beverage Can Europe Limited

Section 2 – Page 6 Back to index < >

France Christophe Casail (+33) 680 891622 christophe.casail@rexam.com

Germany Uwe Schmolling (+49) 1728 468946 uwe.schmolling@rexam.com

Italy Ricardo Bottura (+39) 348 5146375 ricardo.bottura@rexam.com

Section 2 – Page 7 Back to index < >

COUNTRY CONTACT MOBILE NO. EMAIL

Russia Victor Diakov (+7) 095 769 2519 victor.diakov@rexam.com

Spain Joaquin Mingo (+34) 629 792939 joaquin.mingo@rexam.com

Turkey Oguzhan Dirik (+90) 532 214 2731 oguzhan.dirik@rexam.com

UK Graham Fenton (+44) 7774 825292 graham.fenton@rexam.com

Section 2 – Page 8 Back to index < >

CAN AND END MAKING PROCESS

The Can Making Process .... >

The End Making Process .... >

Section 3 – Page 1 Back to index < >

THE CAN MAKING PROCESS

Section 3 – Page 2 Back to index < >

THE CAN MAKING PROCESS

STEP 3 TRIMMER AND WASHER

Section 3 – Page 3 Back to index < >

THE CAN MAKING PROCESS