Revolutionary Resealable Aluminum Can Design Eliminates Spills and Plastic Waste

Plastic bottles are lightweight and leak-proof, but their environmental cost is significant. Aluminum cans are recyclable and convenient, yet prone to spills. ReLid USA has developed a solution that combines the best of both worlds.

ReLid USA has designed a fully recyclable aluminum can featuring a patented resealable tab. The tab operates via a built-in sliding mechanism: lift the tab end and slide it open to drink; slide it back to reseal. According to ReLid, the tabs maintain functionality for at least 14 reseals.

The design and development of these cans began in 2020 by Re-Lid Engineering AG, a packaging design firm based in Liechtenstein. ReLid USA, headquartered in St. Charles, Illinois, holds the exclusive North American license for the technology.

Engineering a Scalable, Recyclable Solution

The primary challenge was creating a product that is recyclable, intuitive, and manufacturable at scale, says Bill Brandell, President and CEO of ReLid USA. The solution had to integrate seamlessly with existing beverage-filling infrastructure without disrupting the current can-filling process.

“The product had to drop in to the current beverage-filling infrastructure without impacting the existing can-filling process.”

— Bill Brandell, President and CEO, ReLid USA

The resealable top is engineered to maintain its seal integrity despite temperature fluctuations or pressure changes from carbonation. ReLid USA states the design is suitable for water, energy drinks, sports drinks, ready-to-drink coffee, wine, and spirits.

Market Differentiation and First Commercial Launch

Beyond functionality, the resealable can serves as an aesthetic differentiator, offering brands a unique and memorable packaging option. ReLid USA is targeting beverage manufacturers seeking premium pricing or a competitive edge.

L.A. Libations, a California-based consumer packaged goods incubator, will be the first to introduce ReLid USA’s resealable tops on canned water. The product will be sold exclusively at Gelson’s, a Southern California grocer, starting in July 2024.

Production Scale and Future Expansion

Currently, a production line in Germany can manufacture 1 million cans per month. These cans will be introduced in small markets initially. ReLid USA plans to open its own production facility in the Central United States in the fourth quarter of 2024.

Competitive Advantage: Plastic-Free Resealable Tabs

While other manufacturers have experimented with resealable can tops, none have achieved widespread scalability. For example, Coca-Cola Co.’s Monster Energy brand introduced resealable can tops in 2009, including cans with bottle tops and plastic resealable mechanisms.

ReLid USA’s solution stands out by using entirely aluminum components, eliminating plastic waste. This feature provides a competitive advantage for beverage manufacturers aiming to reduce plastic usage.

The result is a fully recyclable can that combines the convenience of a bottle with the sustainability and recyclability of an aluminum can.