Increasing demands for efficiency and the continuous optimization of use of resources have been a dominant aspect of beverage can production for years. For the Middle East based Royal Can Making Company, this meant further developing existing processes in a targeted manner and systematically leveraging potential savings. Together with Henkel Adhesive Technologies, the company undertook a comprehensive optimization project at its production site in Sulaymaniyah in 2024. Based on a detailed audit of 2023 production figures, specific measures were defined and implemented during day-to-day operations. The aim was to reduce water and chemical consumption, aluminium scrap and measurably increase overall production efficiency without compromising on quality or production output.
The Royal Can Making Company was founded in 2013 as the first manufacturer of aluminium beverage cans in the Kurdistan Region in Iraq. From its site in Sulaymaniyah and, since 2018, from a second site in Baghdad, the company supplies customers not only across the Middle East, but also in the broader international market. With an annual production of more than six billion cans across both sites as of 2025 in various formats ranging from 150 to 500 millilitres, process stability, consistency of quality and efficient use of resources are of great importance. With this in mind, Royal Can has been working with Henkel Adhesive Technologies for many years to continuously analyse and further develop production processes.
Optimization at full speed: adjustments during ongoing operation
The high production output of the Sulaymaniyah plant left only limited scope for making far-reaching changes to existing processes. At the same time, the key figures from 2023 showed that there was potential for optimization, especially in water and chemical consumption, but also in the amount of aluminium scrap. Improvements had to be planned in detail and tested during short maintenance periods in order to incorporate them into daily operations as seamlessly as possible.
“It was crucial for us that all measures could be quickly integrated into our ongoing operations and that we didn’t have to compromise on quality or system stability,” says Saad Faeq Mohammed Kolak, President of the Royal Can Making Company. “We wanted to make targeted improvements without affecting ongoing production too much.”
“The sustainability goals and long-term vision of the Royal Can Making Company align perfectly with ours at Henkel. To support can makers in producing more sustainably, we continuously develop solutions that help manufacturers meet their individual efficiency targets. To achieve measurable improvements in production sustainability, we rely on technology-driven partnerships, as they provide a strong foundation for the exchange of ideas and expertise,” says Aziz Mabrouki, Director Metal Packaging EIMEA at Henkel.
A key aspect was the holistic view of all processes. In beverage can production, any individual adjustments have a direct impact on subsequent manufacturing steps. Accordingly, the project required a detailed analysis of all settings, flow rates and consumption values, as well as their interactions. In addition, there were production conditions specific to the site’s location.
Systematic analysis: audit and benchmarking for targeted measures
The project’s starting point was a comprehensive audit of procedures. The aim was not to make the greatest possible number of adjustments at the same time, but to identify measures that would have a high impact with the least possible restrictions on ongoing production. Together, Royal Can and Henkel analysed the consumption data and process parameters along the line and defined specific target values for water, chemical and aluminium consumption from there. Henkel’s expertise from similar projects was essential for setting realistic and comprehensive targets. They prioritized adaptations that could be implemented without unscheduled production shutdowns, promised measurable effects quickly and at the same time would create a stable basis for further optimizations.
“It was our responsibility to categorize all the collected data and show which measures had proven successful in comparable projects,” explains Aziz Mabrouki. “This external perspective is often crucial in revealing potential that is overlooked in day-to-day operations.”
After first ensuring that the pre-treatment of all aluminium coils is carried out uniformly with a Henkel Post Lubricant, the subsequent process steps could be analysed and optimized. Coordinating the compatibility of all chemicals used in the various production phases is a fundamental prerequisite for ideal application and a stable process. Maintaining a good film weight of the cupping lubricant Henkel Bonderite L-FM SNL 50-E significantly improved can quality.
The audit also included monitoring flows, returns and fluid supply and their subsequent optimization. Blockages were eliminated, returns improved and configurations adjusted to avoid unnecessary product losses. These measures made a significant contribution to reducing chemical consumption. “Together, we took a very detailed look at the processes and implemented measures step by step,” explains Glenn Ladrillo, Head of Sales APP Metal Packaging MEA at Henkel. “This enabled us to ensure that every adjustment is tangible and becomes firmly anchored in production.”
As Iraq experiences fluctuations between lows of 10 degrees Celsius in the cold winter months and highs of more than 40 degrees Celsius in summer, another important step was to identify an optimal operating temperature for the production process. As the analyses showed, the ideal level varies depending on the products being processed and typically falls within a range of 42 to 46 degrees Celsius. What remains critical across all setups is maintaining a stable operating window with just a ±1°C variation to ensure efficient performance with the biostable metal forming lubricant Henkel Bonderite L-FM450.
Further optimization steps have already been prepared with regard to the ongoing cooperation. They include the use of the Henkel Low Temperature Cleaner and Mobility Enhancer, which aim to further reduce energy and media consumption. Both solutions are already on site for initial tests in production and for implementation in the next project phases.
Reduced resource consumption with a measurable effect
At the start of the collaboration, Royal Can and Henkel set an ambitious roadmap for enhancing efficiency and reducing environmental impact at the Sulaymaniyah site. The outcome surpassed these shared ambitions: The 2024 figures showed substantial reductions across all key resource streams, accompanied by a measurable decrease in the site’s carbon footprint. While chemical consumption fell by 78 tonnes, water consumption was cut by 25 million litres. At the same time, aluminium scrap was significantly reduced. In 2024 alone, Royal Can reduced its use of this valuable raw material by 119,000 kilograms.
The decreased aluminium consumption in 2024 alone led to a saving of 1.8 million kilograms of CO₂ compared to the previous year. Using fewer chemicals enabled an additional reduction of 73,000 kilograms of CO₂. In addition to the quantifiable results, greater process stability in daily operations was evident. Improved can quality, more consistent media flow and optimized settings enable the production team to maintain the achieved standards on a long-term basis. “The adjustments have noticeably stabilized our processes and give us security in our daily operations,” Saad Faeq Mohammed Kolak concludes.