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<p>Sustainable manufacturing is increasingly vital in reducing the carbon footprint of energy-intensive industries. In this context, aluminium alloys, commonly used in food packaging applications such as food trays and wine caps, have a significant carbon footprint due to the energy-intensive electrolytic process used in primary production. Few studies have investigated the combined effects of higher percentages of secondary aluminum on both the environmental impact and mechanical properties of semi-finished products in the packaging industry. To bridge that knowledge gap, this work, conducted in collaboration with Laminazione Sottile S.p.A., investigates the potential of a new aluminium alloy, with a high manganese content and 80% secondary aluminium, on the environmental impact and mechanical properties of food trays and wine caps. For this purpose, a cradle-to-gate Life Cycle Assessment (LCA) and tensile tests were performed to assess, respectively, the environmental and mechanical performance of the above-mentioned semi-finished products. Results show that replacing the conventionally employed alloys with the new one can lead to up to 55% reduction in Global Warming Potential (GWP), Depletion of abiotic resources-fossil fuels (ADPf), and Photochemical Ozone Creation Potential (POCP). Mechanical tests also confirmed that the new alloy can even increase the Ultimate Tensile Strength (UTS), up to 4.2%, and yield strength, up to 18.2%. A sensitivity analysis also highlighted that the increase in the percentage of secondary aluminum has a greater environmental benefit than switching to renewable energy alone, although both strategies enhance performance. In fact, the most substantial environmental increase occurs when the percentage of secondary aluminum is reduced from 80% to 60%, regardless of the energy source, emphasizing the critical role of secondary aluminum in minimizing the overall environmental footprint. These findings provide a viable pathway for the aluminum industry to reduce carbon footprint in packaging applications without compromising product performance, supporting the industry’s transition toward decarbonization and net-zero targets by 2050.</p>

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On the role of secondary aluminum use in minimizing environmental impact in the food packaging industry

  • 期刊论文

  • 出版模式：

    开放获取

  • 发表日期：

    2026年3月18日

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  • Ersilia Cozzolino,
  • Ilaria Papa,
  • Francesca Vitiello,
  • Ciro Sinagra,
  • Antonello Astarita

摘要

Sustainable manufacturing is increasingly vital in reducing the carbon footprint of energy-intensive industries. In this context, aluminium alloys, commonly used in food packaging applications such as food trays and wine caps, have a significant carbon footprint due to the energy-intensive electrolytic process used in primary production. Few studies have investigated the combined effects of higher percentages of secondary aluminum on both the environmental impact and mechanical properties of semi-finished products in the packaging industry. To bridge that knowledge gap, this work, conducted in collaboration with Laminazione Sottile S.p.A., investigates the potential of a new aluminium alloy, with a high manganese content and 80% secondary aluminium, on the environmental impact and mechanical properties of food trays and wine caps. For this purpose, a cradle-to-gate Life Cycle Assessment (LCA) and tensile tests were performed to assess, respectively, the environmental and mechanical performance of the above-mentioned semi-finished products. Results show that replacing the conventionally employed alloys with the new one can lead to up to 55% reduction in Global Warming Potential (GWP), Depletion of abiotic resources-fossil fuels (ADPf), and Photochemical Ozone Creation Potential (POCP). Mechanical tests also confirmed that the new alloy can even increase the Ultimate Tensile Strength (UTS), up to 4.2%, and yield strength, up to 18.2%. A sensitivity analysis also highlighted that the increase in the percentage of secondary aluminum has a greater environmental benefit than switching to renewable energy alone, although both strategies enhance performance. In fact, the most substantial environmental increase occurs when the percentage of secondary aluminum is reduced from 80% to 60%, regardless of the energy source, emphasizing the critical role of secondary aluminum in minimizing the overall environmental footprint. These findings provide a viable pathway for the aluminum industry to reduce carbon footprint in packaging applications without compromising product performance, supporting the industry’s transition toward decarbonization and net-zero targets by 2050.