ELYSIS Carbon-Free Aluminum Debuts in Consumer Packaging: A Game-Changer for Low-Carbon Innovation
Industry Collaboration Delivers One of the Lowest-Carbon Packaging Solutions
Alcoa Corporation, in partnership with Ball Corporation and Unilever, has taken a major leap toward sustainability by introducing the first use of ELYSIS® carbon-free aluminum smelting technology in personal and home care packaging. This innovative move, revealed just before the 30th United Nations Climate Change Conference (COP30), signals an industry milestone in providing lower-carbon packaging solutions for everyday products.
The breakthrough comes in the form of a newly developed aerosol can that blends 50% ELYSIS primary aluminum with 50% post-consumer recycled content. The result? One of the lowest-carbon consumer packaging options currently available, thanks to technology that replaces traditional carbon emissions from smelting with pure oxygen output.
| Innovation Feature | Key Details |
|---|---|
| ELYSIS Technology | Eliminates all direct greenhouse gas emissions from smelting by generating oxygen instead of CO2 |
| First Consumer Use | Aerosol cans made from 50% ELYSIS primary aluminum, 50% post-consumer recycled content |
| Industry Partners | Alcoa, Ball Corporation, Unilever |
| Timing | Announcement made ahead of COP30 global climate summit |
Strong Alignment with Decarbonization and Consumer Sustainability Goals
This collaborative project does more than introduce an innovative packaging solution—it demonstrates a practical model for how companies across the value chain can join forces to accelerate low-carbon innovation. As noted by Alcoa’s Executive Vice President Renato Bacchi, “Through this collaboration with Ball and Unilever, we’re helping bring low-carbon aluminum into everyday products and demonstrating how innovation at the material level can deliver tangible sustainability benefits.”
For Ball Corporation, combining higher recycled content with carbon-free primary aluminum is pivotal for decarbonizing not just their products, but the aluminum industry at large. Ramon Arratia, Chief Sustainability Officer at Ball, highlighted that this is both a packaging breakthrough and a showcase of critical supply chain collaboration at work.
Setting a Precedent for Global Materials Transformation
The ELYSIS process, a result of joint innovation between Alcoa and Rio Tinto with support from Apple and government partners, uses inert anode technology to completely remove greenhouse gas emissions from aluminum smelting. By doing so, it produces oxygen in place of CO2, dramatically reducing the carbon footprint associated with primary aluminum production.
This launch not only offers a lower-carbon alternative for consumers, but also marks a shift toward mainstreaming decarbonized materials. The move arrives at a moment when global leaders are gathering to set more ambitious climate targets—offering a timely and concrete example of how industry can support those efforts.
Key Takeaway: Collaboration and Technology are Shaping the Future of Sustainable Packaging
The debut of ELYSIS aluminum in consumer packaging sends a clear message: meaningful emissions reductions are possible when technology leaders and major consumer brands collaborate. As attention focuses on climate solutions at COP30 and beyond, Alcoa, Ball, and Unilever’s partnership could be a blueprint for scaling innovation across sectors. Investors, regulators, and environmentally conscious consumers will be watching closely as this initiative evolves.
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