Aluminum cans are one of the most widely used beverage packaging options globally, but concerns about their health and safety—from metal migration to chemical coatings—persist among consumers and regulators. In 2025, with stricter food safety standards (e.g., FDA’s Food Contact Substances (FCS) regulations, EU’s Regulation (EC) No 1935/2004) and increased transparency requirements, understanding the scientific basis of these concerns is critical. Below is a evidence-based analysis of aluminum can safety, drawing on research from the FDA, EFSA (European Food Safety Authority), and the World Health Organization (WHO).   A primary concern is aluminum migration—the transfer of aluminum from the can to the beverage. Aluminum is a naturally occurring element, and humans ingest small amounts daily from food, water, and air (the WHO sets a safe intake limit of 1mg per kg of body weight per week). Studies by the EFSA show that aluminum migration from intact cans is minimal: for non-acidic beverages (e.g., water, beer), migration levels are <0.05mg per liter (well below the WHO limit), while for acidic beverages (e.g., soda, fruit juice), levels rise to 0.1–0.3mg per liter—still within safe thresholds. The key factor limiting migration is the food-grade liners applied to the interior of aluminum cans. These liners (typically made of epoxy resins or polyester) create a physical barrier between the aluminum and the beverage, reducing migration by 95% compared to unlined cans. In 2025, all major can manufacturers (e.g., Ball Corporation, Crown Holdings) use liners that meet FDA and EFSA standards, with no detectable migration of harmful compounds.   Another focus is the safety of liner materials, particularly concerns about BPA (bisphenol A). BPA is a chemical once used in epoxy liners to enhance durability, but studies linked high doses to hormonal disruptions. In response, the industry has largely phased out BPA: by 2025, 99% of aluminum can liners are BPA-free, using alternatives like bisphenol F (BPF) or bisphenol S (BPS) or non-bisphenol resins (e.g., polyester-based liners). Research by the FDA confirms that BPF and BPS have minimal hormonal activity—their migration levels are <0.001mg per liter, and long-term studies show no adverse health effects at these doses. The EU has gone further, banning all bisphenol-based liners in children’s beverage cans (e.g., juice boxes) in 2025, requiring 100% non-bisphenol liners for these products.   Microbial contamination is a risk for all beverage packaging, but aluminum cans offer strong microbial barrier properties. Unlike plastic bottles (which can be punctured or have loose caps) or paper cartons (which absorb moisture), aluminum cans are hermetically sealed during filling—this prevents bacteria, mold, and yeast from entering the beverage. Studies by the International Society for Food Protection (ISFP) show that aluminum cans have a microbial contamination rate of <0.01% (vs. 0.5% for plastic bottles and 0.2% for cartons). However, contamination can occur if cans are damaged (e.g., dented, punctured) or if filling facilities have poor hygiene. To mitigate this, can manufacturers and beverage brands follow strict GMP (Good Manufacturing Practices): cans are sterilized before filling, and filling lines are cleaned hourly to prevent cross-contamination. In 2025, many facilities also use AI-powered quality control to detect damaged cans before they are filled.   Heavy metal contamination is another concern, but aluminum cans are highly regulated in this area. The FDA and EU set strict limits on heavy metals (e.g., lead, cadmium, mercury) in aluminum used for food packaging: lead levels must be <0.1mg per kg of aluminum, and cadmium <0.01mg per kg. These limits are enforced through third-party testing—all aluminum used for cans is certified as “food-grade” before production. Additionally, the use of recycled aluminum (now 50%+ of can content globally) does not increase heavy metal risk: recycling facilities use magnetic separation and chemical purification to remove heavy metals from scrap aluminum, ensuring recycled material meets the same standards as virgin aluminum. A 2025 study by the Aluminum Association found no difference in heavy metal levels between cans made from 100% virgin aluminum and 100% recycled aluminum.   Consumer handling also impacts safety. To minimize risks, experts recommend: avoiding storing aluminum cans in extreme temperatures (e.g., direct sunlight for weeks, which can degrade liners slightly); not drinking from dented or punctured cans (which may compromise the liner); and washing the can top before opening (to remove dust or bacteria from transportation). These simple steps further reduce any potential safety risks, though the scientific consensus is that intact, properly handled aluminum cans are among the safest beverage packaging options.   In conclusion, aluminum cans are safe for beverage use when manufactured and handled correctly. Regulatory standards, BPA-free liners, minimal aluminum migration, and strong microbial barriers ensure they meet the highest health and safety requirements. For consumers and brands, choosing aluminum cans means prioritizing both sustainability and safety—two critical factors in 2025’s beverage packaging landscape.