White paper: combatting rust in canned beverages – NXT process’ innovation-driven solution

White Paper: Combatting Rust in Canned Beverages

NXT Process’ Innovation-Driven Solution

Executive Summary

Rusting in beverage cans—particularly aluminum—poses a significant threat to product integrity, shelf life, and brand reputation. This degradation is especially pronounced in what the industry refers to as “hard-to-hold” beverages: formulations with high acidity, dissolved oxygen (DO), or other aggressive compounds.
At NXT Process, our integrated, engineering-led approach offers a powerful solution to this problem. By controlling DO levels at critical process points and selecting corrosion-resistant equipment tailored to each application, we deliver both technical precision and operational reliability.

I. The Problem: Rust in Beverage Cans

Aluminum begins to degrade in the presence of oxygen primarily due to corrosion, which is significantly accelerated in moist environments and in contact with certain food or beverage products. In the context of aluminum beverage cans, the parts per billion (ppb) oxygen level that can initiate or accelerate degradation depends on several factors including pH, presence of electrolytes (like salts), and time.

⚠️ Key Thresholds for Oxygen-Induced Degradation

• Below 50 ppb O₂: Generally considered safe in most beverage applications.
• Above 100 ppb O₂: Begins to pose a corrosion risk, especially if the beverage is acidic.
• Above 200–300 ppb O₂: Strong risk of visible aluminum corrosion.

📌 Additional Factors

• pH: Low pH beverages are more aggressive.
• CO₂: Increases acidity.
• Coating Integrity: Microdefects can expose metal.
• Storage Conditions: Heat and humidity accelerate degradation.

1.1 Root Causes of Corrosion

• Elevated dissolved oxygen (DO)
• Acidic pH levels
• Defective or degraded internal coatings
• Micro-cracks in lacquer linings
• Long shelf lives

1.2 Consequences

• Swelling or leakage of cans
• Metal leaching into the beverage
• Product recalls and lost revenue
• Incompatibility with standard canning

II. Traditional Solutions and Their Limitations

• Resin-based linings and CO₂ purging are insufficient
• Costly and inefficient product carbonation

III. NXT Process: Engineering a Modern Solution

3.1 Inline Deoxygenation Systems

• Ideal for process water
• Reduce DO to <10 ppb
• Operate inline with real-time control

NXT Deox:

Our in-line membrane deoxygenation system removes almost all oxygen from the water in just a few minutes. View this product 

3.2 Overall Process Thinking

• Full lifecycle approach
• Integrated automation, equipment, and controls
• System-wide oxygen risk management
• Cross-functional collaboration

3.3 Complementary Technologies

• In-line mixers: closed-loop, oxygen-free
• Wise CO₂ usage: oxygen barrier and stabilization
• Inline O₂/CO₂ monitoring tools: ensure TPO compliance

Pentair-Haffmans Gehaltemeter:
Proven Precision for CO₂ and O₂ Measurement in Beverages. View this product

IV. NXT’s Added Value

4.1 Deep Process Understanding

• Full solution architecture in food & beverage

4.2 Speed & Agility

• Rapid quoting and design
• Agile manufacturing
• Efficient commissioning and training

4.3 Customer-Centric Execution

• End-to-end project ownership
• Commitment to resolution

Let’s talk about making corrosion in cans a thing of the past.

Contact: p.gauthier@nxtprocess.com | www.nxtprocess.com