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Our top-rated recyclable PET cans and cups, purpose-built for airline catering, lounge service, and in-flight beverage distribution.
How the aviation industry is reshaping in-flight packaging standards with sustainable, lightweight PET solutions.
The global aviation industry serves over 4.5 billion passengers annually, and every single flight generates a significant volume of single-use packaging waste — from aluminum cans and glass bottles to plastic cups and stirrers. As airlines face mounting regulatory pressure from ICAO, IATA, and regional environmental bodies, the search for a smarter, greener in-flight beverage container has never been more urgent. The answer that is rapidly gaining traction across the industry: Recyclable PET (Polyethylene Terephthalate) cans.
PET cans are up to 50% lighter than aluminum cans and fully recyclable — a dual advantage that simultaneously reduces aircraft fuel consumption and minimizes environmental footprint at 35,000 feet.
As of 2024, the global PET can market is valued at approximately USD 1.2 billion and is projected to grow at a CAGR of over 7.5% through 2030, driven heavily by the food and beverage sector — with aviation catering emerging as one of the fastest-growing sub-segments. Major airlines in Europe, North America, and Asia-Pacific have already begun transitioning portions of their in-flight beverage service from traditional aluminum or glass to recyclable PET cans and cups.
Airlines such as Lufthansa, Singapore Airlines, and several low-cost carriers have publicly committed to eliminating single-use plastics that cannot be recycled and replacing them with certified recyclable alternatives. PET cans, which are accepted by most municipal and industrial recycling streams worldwide, fit perfectly into this transition strategy. Their compatibility with existing aluminum can filling lines — particularly those using 202 SOT (Sanitary Open Top) ends — also makes adoption significantly easier for established beverage brands and airline catering suppliers.
In-flight service presents a uniquely demanding set of requirements for beverage packaging. Containers must be lightweight to minimize payload and fuel burn, structurally robust enough to withstand pressurized cabin conditions, food-safe and free from harmful chemicals, easy to open and handle in a confined space, and visually appealing enough to enhance the passenger experience. PET cans check every single box.
Every kilogram of weight removed from an aircraft translates directly into fuel savings. A standard aluminum can weighs approximately 15–17 grams, while a comparable PET can weighs just 10–12 grams. Across a fleet of 200 aircraft, each serving 150 passengers with two beverages per flight, the cumulative weight reduction is substantial — potentially saving thousands of tonnes of CO₂ emissions annually. For airlines with aggressive net-zero targets, this is not a marginal gain; it is a strategic imperative.
Unlike glass bottles, PET cans will not shatter if dropped during turbulence — a critical safety consideration in the confined, high-movement environment of an aircraft cabin. Their resilience makes them far safer for flight attendants and passengers alike, reducing the risk of injury and simplifying in-flight service protocols.
PET is one of the most widely recycled plastics in the world, with established collection and processing infrastructure in over 150 countries. Airlines that collect used PET cans post-flight can divert them directly into certified recycling streams, contributing to a circular economy model. RPET (Recycled PET) cans — made from post-consumer PET material — take this a step further, closing the loop entirely and enabling airlines to demonstrate measurable sustainability credentials to ESG-conscious investors and passengers.
PET cans offer 360-degree printable surfaces with exceptional color fidelity and gloss. Airlines can leverage custom-printed PET cans as a powerful brand touchpoint — featuring route maps, destination artwork, seasonal campaigns, or loyalty program promotions directly on the can body. This level of personalization is difficult and expensive to achieve with standard aluminum cans, but is readily accessible with modern PET printing technology.
PET cans designed with 202 SOT ends are dimensionally compatible with standard aluminum can filling and seaming equipment. This means beverage producers and airline catering suppliers can adopt PET cans without investing in entirely new production lines, dramatically lowering the barrier to entry and accelerating adoption timelines.
The next decade will see transformative shifts in how airlines source, use, and manage in-flight beverage packaging.
The shift from virgin PET to RPET (Recycled PET) and emerging bio-based PET resins is accelerating. Airlines are increasingly specifying minimum recycled content thresholds — often 30–50% RPET — in their packaging procurement criteria. Bio-PET, derived from sugarcane or corn starch, offers a carbon-neutral alternative that is gaining regulatory and consumer acceptance.
Integration of NFC chips, QR codes, and digital watermarks into PET can designs is enabling airlines to connect passengers with digital content — from in-flight entertainment menus to destination guides and loyalty rewards — directly through their beverage container. This "smart can" concept is already being piloted by several premium carriers.
The EU Single-Use Plastics Directive, ICAO's Carbon Offsetting and Reduction Scheme (CORSIA), and similar regulations in Asia-Pacific are pushing airlines toward packaging that is demonstrably recyclable and traceable. PET cans — with established recycling infrastructure and clear material identification — are well-positioned to meet these evolving compliance requirements.
Digital printing advances are enabling short-run, highly customized PET can designs at competitive cost points. Airlines can now produce limited-edition cans for specific routes, seasonal promotions, or partnership campaigns with minimal setup cost — a marketing flexibility that aluminum cans simply cannot match at equivalent volumes.
Forward-thinking carriers are establishing dedicated post-flight PET collection and recycling partnerships, creating closed-loop systems where used PET cans are processed back into new packaging. This circular model not only reduces waste but generates verifiable sustainability data that can be reported to regulators and shareholders.
Continuous advances in PET wall thickness optimization and multi-layer barrier coatings are enabling thinner, lighter cans that maintain full structural integrity and product shelf life. These innovations directly support airline payload reduction targets while preserving beverage quality across extended supply chains and high-altitude storage conditions.
From economy class trolley service to first-class lounge experiences, PET cans are transforming every touchpoint of airline beverage delivery.
PET cans are perfectly sized for standard beverage trolley configurations and can be pre-filled and sealed with carbonated soft drinks, juices, water, or sparkling beverages. Their lightweight nature reduces trolley load, easing the physical burden on flight attendants and improving service speed during peak distribution windows. Transparent PET variants also allow passengers to visually confirm product contents, enhancing trust and satisfaction.
For premium cabins and airport lounges, custom-printed PET cans with premium finishes — including frosted, metallic, or full-color photographic prints — deliver a luxury aesthetic that rivals glass. Airlines can offer signature cocktails, premium juices, or proprietary beverage blends in branded PET cans that reinforce their premium positioning while maintaining the sustainability credentials demanded by high-net-worth, ESG-aware passengers.
Specialized PET cup and can formats — including heat-resistant variants and flat-lid coffee cups — are enabling airlines to serve hot beverages in recyclable PET containers for the first time. PET coffee cups with flat lids offer a spill-resistant, lightweight alternative to ceramic or polypropylene cups, reducing breakage risk and simplifying post-flight waste sorting and recycling.
Airlines serving families and children can leverage smaller-format PET cans (150ml–250ml) for juice, flavored water, or bubble tea service as part of children's meal kits. The shatter-proof, lightweight, and BPA-free properties of PET make these containers inherently safer for young passengers, while fun custom printing options allow airlines to create engaging, kid-friendly can designs that enhance the overall travel experience.
PET cans are increasingly being adopted for onboard retail and duty-free beverage sales. Their ability to be custom-printed with high-resolution branding, their stackability for efficient cabin storage, and their recyclable credentials make them an ideal format for premium spirits, craft beverages, and specialty drinks sold as retail products during flight. Pop-top and SOT-end PET cans offer easy opening without additional tools — a critical convenience factor in the in-flight retail context.
For charter airlines, regional carriers, and low-cost operators where weight and cost efficiency are paramount, recyclable PET cans offer a compelling value proposition. Their lower unit weight versus aluminum reduces fuel costs across high-frequency short-haul operations, while their compatibility with standard filling lines enables beverage suppliers to serve both traditional and emerging airline clients without infrastructure changes. The cost-competitiveness of PET at scale also makes it accessible for carriers operating on thinner margins.
Established in 2021, Shanghai COPAK Industry Co., Ltd. maintains a sales office in Shanghai and an associated factory in Guangdong Province. As a professional supplier of eco-friendly food and beverage packaging solutions, our product portfolio includes PET cups, PET cans, and sealing machines, among other related items.
Committed to staying ahead of market trends through continuous innovation, COPAK delivers high-quality yet cost-effective packaging solutions. Our product range covers PET cups and cans in diverse shapes and capacities — from 1oz to 32oz — available in both plain finishes and custom printed designs. As a long-term strategic partner and trusted supplier, we dedicate ourselves to designing and manufacturing reliable, premium-quality, and stylish PET cups and cans for our clients.
Our optimized facility and advanced equipment are governed by stringent quality control, ensuring efficient, high-standard production of airline-grade PET beverage cans.
Our factory is situated in a well-connected industrial zone, enabling efficient distribution via convenient transportation networks. The spacious and well-organized facility features dedicated areas for raw material storage, production lines, quality control, packaging, and logistics operations.
We are equipped with state-of-the-art blow molding machines specifically engineered for PET cup and PET can production, enabling high-speed manufacturing without compromising precision or quality. Our factory also houses injection molding machines and advanced printing equipment to support custom branding needs.
Our dedicated quality control department is equipped with specialized testing equipment to ensure all PET cups and PET cans adhere to stringent quality standards. Key inspection items include wall thickness uniformity, dimensional accuracy, visual defect screening, and material integrity verification.
COPAK is committed to sustainable development and has implemented targeted initiatives to minimize energy consumption, reduce waste generation, and promote material recycling. These include the adoption of energy-efficient production processes, robust waste management systems, and the integration of recycled PET materials into our cup and can manufacturing.
Our recyclable PET cans are designed to support airlines' net-zero commitments — offering a packaging solution that is lighter, greener, and fully aligned with the circular economy principles that define the future of aviation.
Contact UsWe offer extensive customization options to meet the unique requirements of beverage brands and airline clients, including tailored shapes, sizes, and capacities for PET cups and cans. We provide full support for custom mold development and personalized printing solutions.
Adhering to global food-grade packaging regulations and standards, our factory holds various authoritative certifications, including ISO 9001, FDA, CE, ROHS, and EU No. 10/2011. These certifications underscore our unwavering commitment to producing safe, high-quality beverage packaging products.
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Our dedicated R&D team focuses continuously on product innovation and technological advancement. The team specializes in developing innovative packaging solutions, optimizing production processes, and exploring sustainable materials and technologies to drive industry progress.
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We have established a streamlined logistics system to ensure efficient product distribution. This encompasses well-managed warehousing, precise inventory control, and close coordination with trusted transportation partners, guaranteeing timely and reliable delivery to clients worldwide.
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Over 20 production lines for rapid order fulfillment
Fully automated, hands-free production equipment
100,000-class cleanroom workshop
Free samples available upon request
Free replacements for products with critical defects
Explore our full range of recyclable PET cans, cups, and containers engineered for every in-flight and airport catering application.
Having supplied PET cups and PET cans to numerous renowned brands and airline catering partners, our products are now distributed globally. Partner with COPAK for a dependable, trustworthy collaboration and achieve mutual success through win-win cooperation.
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