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Metal packaging offers robust, recyclable solutions for diverse industries. This review details material designs, safety, and sustainability for advanced metal packaging systems.

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Area of Science:

  • Materials Science and Engineering
  • Packaging Technology
  • Sustainable Manufacturing

Background:

  • Metal packaging is crucial in food, pharma, and cosmetics due to its protective properties and recyclability.
  • Diverse metal packaging architectures exist, including aluminum, tinplate, TFS/ECCS, stainless steels, MMCs, and laminates.
  • Material design significantly impacts packaging performance, including formability, barrier properties, and longevity.

Purpose of the Study:

  • To provide a comprehensive review of metal-based packaging architectures from a materials and systems perspective.
  • To link material composition, microstructure, processing, and surface engineering to functional performance.
  • To discuss safety, regulatory, and circularity considerations in metal packaging design.

Main Methods:

  • Systematic review of existing literature on metal packaging materials and systems.
  • Analysis of material properties, processing techniques, and surface engineering approaches.
  • Evaluation of safety, regulatory compliance, and end-of-life management.

Main Results:

  • Detailed examination of various metal packaging architectures (alloys, TFS/ECCS, MMCs, laminates).
  • Discussion on the shift towards BPA-free coatings and the use of nanostructured surfaces.
  • Assessment of ion migration, corrosion, and coating integrity against regulatory standards (EU, FDA, ISO).

Conclusions:

  • Metal packaging design requires a holistic approach, integrating material selection, processing, performance, and sustainability.
  • The recyclability of aluminum and steel contrasts with challenges in managing coated metals and laminates.
  • Advanced metallic and hybrid architectures are key to ensuring functional reliability and life-cycle sustainability in packaging.