In the packaging of beverages, variations between the dimensions of 500ml can sizes and 330ml can formats do impact cost factors and business strategy. Utilize conventional aluminum cans as an example. 500ml cans will possess outer diameter typically ranging from 66.0±1.5mm to 168-178mm in height, whereas the diameter of 330ml can is a fixed 66.0mm and the height is 122mm (data by European Beverage Can Makers Association). Despite a 51.5% increase in capacity, the aluminum usage of 500ml cans was only 37% greater than that of 330ml cans (single can weight 23 grams vs 16.8 grams), and the aluminum usage per milliliter decreased by 9.6% (Ball Corporation’s 2024 Sustainability report).
The cost comparison of production is significant. Coca-Cola’s computation shows that filling line speed for 500ml cans is 1,800 cans per minute, 10% lower than 330ml cans’ speed at 2,000 cans. However, filling a can of drink is 16% cheaper (0.021 US dollars) compared to 330ml cans (0.025 US dollars). Ab InBev improved ring crush strength to 310 pounds (using the ASTM D4169 standard) by optimizing the shoulder Angle of the 500ml can size (from 70° to 75°), a growth of 8% compared to that of the 330ml can. Transport break percentage decreased from 0.7% to 0.3% (Supply Chain Annual Report 2023).
Efficiency in logistics shows nonlinear growth. DHL research reveals that the holding capacity of 40-foot containers with 500ml tanks is 180,000 tanks, 25% less than the capacity of 330ml tanks at 240,000 tanks. However, the unit cost of transportation for the value of goods (0.0035 US dollars /ml) continues to be 14.6% less compared to 330ml tanks (0.0041 US dollars /ml). Suntory Japan has upgraded the pallet layer height from 15 to 16 stacks by reducing the 500ml tank height from 172mm to 167mm, thereby enhancing the warehouse space use rate by 12% (a case of logistics improvement in 2024).
Consumer behavior statistics reflect market segmentation. A Nielsen survey indicates 500ml cans are responsible for 68% of off-trade sales, and 330ml cans hold 73% in ready-to-drink outlets (convenience stores/vending machines). Starbucks’ 500ml cold brew coffee can has a 30% shorter repeat purchase cycle than the 330ml version due to its capacity being suitable for office environments. The incomplete rate of one drink, however, has risen from 12% to 24% (Kantar 2024 Consumer Study). Red Bull increased vending machine stocking density of cans by 19% by reducing the 500ml can dimensions sizes to 64.5mm (66.0mm for 330ml cans), but sales time per can rose by 14 seconds, affecting turnover efficiency.
Differential design is motivated by environmental protection legislation. The EU’s “Green Deal” requires the recycled aluminum content of 500ml cans to be 65% by 2025 (55% for 330ml cans), which forces the manufacturers to redesign the can wall structure. Novelis’ Advanz™ alloy (thickness of 0.21mm) for 500ml cans is 12% thinner than for 330ml cans (thickness of 0.24mm). However, it has a compressive strength of 45psi and reduces its carbon footprint by 23% (life cycle assessment report 2024). The Chinese standard GB 4806.9-2023 demands that the weld overlap ratio of 500ml tanks should be ≥15% (≥12% for 330ml tanks), adding 7% to the manufacturing cost, but the pass rate of the drop test has been boosted from 91% to 97%.
Market strategy influences parameter optimization. Carlsberg’s Slim can of 500ml (64.8mm diameter) launched in Asia saves 9% of the use of aluminum compared to the regular can, while the 330ml can typically requires embossing print due to ruthlessly competitive price pressures (raising the price by $0.008 per can). According to Yanki Forest’s data, the average price per transaction of 500ml cans in the supermarket channel is 3.9 yuan, which is 39% higher than that of 330ml cans (2.8 yuan), but the profit margin per milliliter is 8% lower. North American 500ml cans of Pepsi-Cola increased the drinking frequency by 22% by expanding the can mouth to 55mm (53mm for the 330ml can), and the blind taste rating was enhanced by 14% (Cornell University Sensory Experiment).
Technology innovation redefines the cost performance balance. The Orikin 500ml variable diameter tank (62mm at top / 66mm at bottom) enhances stacking stability by 20% and offers 18% more empty tank transport volume than the 330ml tank. Data from KHS filling machines show that it costs 45 minutes to change a 500ml production line to a 330ml specification (68 minutes to reverse switch), which in time cost varies by 51%.
According to the Euromonitor International forecast, world market share of 500ml containers will be 41% in 2025 for the first time more than that of 330ml containers (38%). The reason for its success is the perfect proportioning of dimensions of 500ml cans among economy of capacity, flexibility towards situations and legislative demands. It is a deliberate shift of drinks packaging from standardization towards demand segmentation.