Tata Steel has invested in a D&I bodymaker at its R&D facilities in the Netherlands to test the production of food cans in what it calls a “dry-forming process” to save energy and water use. The initiative marks a significant step toward sustainable packaging manufacturing, aiming to revolutionize traditional can-making techniques that typically rely on wet lubrication systems.​

The dry-forming process eliminates the need for liquid coolants and lubricants during the can body forming stage, reducing water consumption by up to 90% compared to conventional methods. Tata Steel’s new D&I (Draw & Iron) bodymaker at its IJmuiden R&D center integrates advanced mechanical lubrication systems and heat-resistant tooling to maintain precision without liquid agents. Preliminary tests show the process can produce up to 300 cans per minute while cutting energy use by 15%, primarily through reduced wastewater treatment and heating requirements.

This innovation aligns with our commitment to circular economy principles,” said a Tata Steel spokesperson. “By eliminating liquid lubricants, we not only conserve resources but also reduce the environmental footprint of metal packaging.” The technology could address growing industry concerns about water scarcity in manufacturing hubs, particularly in regions like India and Southeast Asia where water-intensive processes face regulatory scrutiny.​

Industry analysts note that if scaled commercially, the dry-forming process could disrupt the $32 billion two-piece can market. Major food processors are already expressing interest in sustainable packaging solutions, with brands like Nestlé and Unilever prioritizing suppliers with low-carbon manufacturing methods. Tata Steel plans to complete pilot trials by Q4 2025 and is in talks with European can-makers to license the technology, positioning itself as a leader in eco-friendly metal packaging innovation.​