How Ball is Expanding Sustainable Aluminium Manufacturing

Ball Corp, a leading manufacturer of sustainable aluminium packaging solutions for beverage, personal care and household products, has recorded a strong 2025 in its annual report.

In 2025, it shipped 111.9bn units of aluminium packaging worldwide and recorded USD$13.16bn in net sales.

The news comes as Ball exceeds sustainability targets and expands its manufacturing operations worldwide, including in North America and India. 

Expanding global manufacturing 

Ball reported it has been expanding its manufacturing operations worldwide, with new sites spanning Europe and North America, as well as further investment in Asia. 

In 2025, Ball acquired an aluminium can manufacturing facility in Winter Haven, Florida, strengthening its North American manufacturing networks. 

In January 2025, Ball acquired a majority stake (80%) in Benepack, a beverage can manufacturing business with two production facilities in Belgium and Hungary.

Ron Lewis, CEO of Ball says: "Benepack's plants in Belgium and Hungary are well positioned to serve a growing base of beverage customers across Europe.

"This investment further optimises our European manufacturing network, supports long-term volume and EVA dollar growth with key customers and reinforces aluminium beverage cans as a sustainable, scalable packaging choice."

In India, Ball is expanding investments in its Sri City plant to support India’s beverage can market.

Emissions and electricity in manufacturing 

In 2025, 84% of Ball's global electricity usage came from renewable sources.

Ball has reported a 50% reduction from its 2017 baseline in Scope 1 (during production emissions) and Scope 2 emissions (off-site emissions). 

Ball expects to achieve its 2030 target of a 55% reduction in total emissions and estimates it will do this ahead of schedule. 

Across multiple manufacturing sites, Ball improved electricity intensity in 2025 by upgrading compressed air and vacuum systems in its processes.

The Ball plant in Fosie, Sweden contributed to electricity savings by upgrading the plant’s vacuum pumps which reduced electricity consumption by 1,032,000 kW hours annually.

Ball is exploring additional renewable energy solutions globally, including off-site and behind-the-meter projects, battery energy storage and microgrid solutions for its manufacturing sites.

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Sustainable aluminium manufacturing

According to McKinsey, major customers in the packaging industry are setting high recycled-content targets for materials, including aluminium.

McKinsey argues that recycling aluminium, especially from postconsumer scrap, could be a more efficient and faster gateway to achieving net-zero emissions

Ball has a 2030 target of 85% recycled content and is working with aluminium suppliers to incorporate sustainability commitments into contracts to try and achieve this goal.

In 2025, 74% of the aluminium used by Ball's global beverage packaging business came from recycled sources. 

A clear strategy

Ball has recorded a strong year in its 2025 report with 111.9bn units of aluminium packaging shipped globally and USD$13.16bn recorded in net sales.

Ron says: "2025 was a record-breaking year with our global team delivering exceptional results.

"Staying close to our customers is more important than ever and that proximity is helping us innovate, grow and deliver value faster. We continue to scale and standardise our operations to fully leverage our manufacturing expertise and expanding footprint, serving our customers when and where they need us most. 

“Our belief in aluminium is bolstered by its superior sustainability, quality and efficiency. Looking ahead, we have a clear strategy in place and a team dedicated to delivering value for our shareholders and making a difference for our company, our customers and our communities."