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  • A new kind of aerosol can

    DS Containers (DSC) are producers of stylish two-piece aerosol cans which are supplied to many US well-known brand owners.  Adopting Protact laminated steel has enabled DSC to offer sustainable cans with high shelf appeal whilst maximising manufacturing flexibility.

    Detailed Information

    Summary

    Summary

    • More efficient manufacturing

      Dedicated ‘coil to can’ supply allows for complete manufacturing flexibility.

    • Photoreal finish

      White Protact® provides a printed, photoreal finish and high quality can decoration.

    • Sustainable aerosols

      DS Containers produces laminated two-piece aerosol cans with enhanced environmental credentials.


    DS Containers (DSC) is a startup founded in 2003 as a partnership between Daiwa Can Company and Bill Smith Sr.  Fundamental to the startup’s success is the use of laminated steel, like Tata Steel’s Protact®, to produce two-piece aerosol cans. In fact, DSC is the only producer of laminated two-piece aerosol cans in the world. 

    Early on, Tata Steel’s Research and Development team worked with Illinois-based DS Containers to optimise the company’s lines for Protact laminated steel

    Protact allows us to create an outstanding two-piece aerosol can, with a vibrant photoreal finish whilst offering maximum flexibility to customers through shorter lead times on aerosol can production and smaller minimum quantity orders compared to industry standards. And all this with improved environmental and sustainability credentials

    Matt Kuehn, Vice President – Sales, Marketing, and Technical Support.


    DS Containers now has a significant share of the aerosol market in the US supplying many well-known brands and in 2017, the company also extended its new manufacturing facility to add debossing capabilities.

    Challenge

    Challenge


    The aerosol canmaking industry has traditionally been dominated by three-piece can production. This has often required customers to order large volumes, 50K+ units, at any one time.  This involves lengthy lead times, which do not always suit the fast-paced manufacturing world. In addition, can makers are constantly looking to improve the environmental credentials of the manufacturing process by lowering emissions, water and energy usage. 

    To meet these industry challenges, DS Containers developed a two-piece aerosol can utilising the unique characteristics of polymer-laminated steel, Protact. 

    Protact features a steel substrate with a polymer coating system of three layers, consisting of an adhesion layer, a main layer and a surface layer, on each side.  This polymer coating system is not susceptible to corrosion from liquids, such as shaving foam or hair mousse and the flexible laminate prevents can end deterioration making it a good choice for steamy, humid environments you would typically find in a bathroom.

    Solution

    Solution


    Stand out aerosol cans

    To create a stand out aerosol can, DS Containers uses dry offset printing, straight onto white Protact. This is a mid-stream process, where the can is already in its cylindrical shape. The ink is applied to the surface comprising up to eight different colours at a time.

    The team can achieve a photoreal finish through its laser-engraved printing plates. And with white Protact as the base, the printed colours really stand out helping to catch the consumer’s eye.

     

    Maximum manufacturing flexibility

    One of the main benefits of using Protact is the ability to create a single in-line manufacturing process. From coil to can, DSC provides an uninterrupted flow through the manufacturing line which creates a significantly more efficient process.

    This enhanced speed and flexibility helps brand owners realise new designs in often just a fortnight compared to the industry standard lead time of six to eight weeks.

    DSC is also able to offer lower minimum order quantities – just 15,000 units compared to 50,000. This dexterity means the company can serve a wider customer base by presenting affordable and efficient production options to smaller and medium-sized businesses.

     

    Heightened sustainability credentials

    DSC’s two-piece process has eliminated the top dome (or cone) component, needed in three-piece canmaking. The product incorporates an integral dome which allows the can to be up to 10 per cent lighter compared to other three-piece varieties

    Protact also allows DSC to eliminate the coating and the shearing steps needed in traditional D&I canmaking and reduces water consumption by removing can washing stages, yet the lubricity of Protact still enables the canmaker to build a deep drawn can.

    Protact’s specialist polymer laminate also means that DSC has been able to remove solid born coatings or lacquers completely from the processing line. This has helped the company grow business in markets where there can be sensitivity regarding coatings such as with BPA in the food sector. Protact ensures that the company remains future proof as no active chemicals are used at all in its polymer coating.

    Gallery

    Gallery

    Summary

    • More efficient manufacturing

      Dedicated ‘coil to can’ supply allows for complete manufacturing flexibility.

    • Photoreal finish

      White Protact® provides a printed, photoreal finish and high quality can decoration.

    • Sustainable aerosols

      DS Containers produces laminated two-piece aerosol cans with enhanced environmental credentials.


    DS Containers (DSC) is a startup founded in 2003 as a partnership between Daiwa Can Company and Bill Smith Sr.  Fundamental to the startup’s success is the use of laminated steel, like Tata Steel’s Protact®, to produce two-piece aerosol cans. In fact, DSC is the only producer of laminated two-piece aerosol cans in the world. 

    Early on, Tata Steel’s Research and Development team worked with Illinois-based DS Containers to optimise the company’s lines for Protact laminated steel

    Protact allows us to create an outstanding two-piece aerosol can, with a vibrant photoreal finish whilst offering maximum flexibility to customers through shorter lead times on aerosol can production and smaller minimum quantity orders compared to industry standards. And all this with improved environmental and sustainability credentials

    Matt Kuehn, Vice President – Sales, Marketing, and Technical Support.


    DS Containers now has a significant share of the aerosol market in the US supplying many well-known brands and in 2017, the company also extended its new manufacturing facility to add debossing capabilities.

    Challenge


    The aerosol canmaking industry has traditionally been dominated by three-piece can production. This has often required customers to order large volumes, 50K+ units, at any one time.  This involves lengthy lead times, which do not always suit the fast-paced manufacturing world. In addition, can makers are constantly looking to improve the environmental credentials of the manufacturing process by lowering emissions, water and energy usage. 

    To meet these industry challenges, DS Containers developed a two-piece aerosol can utilising the unique characteristics of polymer-laminated steel, Protact. 

    Protact features a steel substrate with a polymer coating system of three layers, consisting of an adhesion layer, a main layer and a surface layer, on each side.  This polymer coating system is not susceptible to corrosion from liquids, such as shaving foam or hair mousse and the flexible laminate prevents can end deterioration making it a good choice for steamy, humid environments you would typically find in a bathroom.

    Solution


    Stand out aerosol cans

    To create a stand out aerosol can, DS Containers uses dry offset printing, straight onto white Protact. This is a mid-stream process, where the can is already in its cylindrical shape. The ink is applied to the surface comprising up to eight different colours at a time.

    The team can achieve a photoreal finish through its laser-engraved printing plates. And with white Protact as the base, the printed colours really stand out helping to catch the consumer’s eye.

     

    Maximum manufacturing flexibility

    One of the main benefits of using Protact is the ability to create a single in-line manufacturing process. From coil to can, DSC provides an uninterrupted flow through the manufacturing line which creates a significantly more efficient process.

    This enhanced speed and flexibility helps brand owners realise new designs in often just a fortnight compared to the industry standard lead time of six to eight weeks.

    DSC is also able to offer lower minimum order quantities – just 15,000 units compared to 50,000. This dexterity means the company can serve a wider customer base by presenting affordable and efficient production options to smaller and medium-sized businesses.

     

    Heightened sustainability credentials

    DSC’s two-piece process has eliminated the top dome (or cone) component, needed in three-piece canmaking. The product incorporates an integral dome which allows the can to be up to 10 per cent lighter compared to other three-piece varieties

    Protact also allows DSC to eliminate the coating and the shearing steps needed in traditional D&I canmaking and reduces water consumption by removing can washing stages, yet the lubricity of Protact still enables the canmaker to build a deep drawn can.

    Protact’s specialist polymer laminate also means that DSC has been able to remove solid born coatings or lacquers completely from the processing line. This has helped the company grow business in markets where there can be sensitivity regarding coatings such as with BPA in the food sector. Protact ensures that the company remains future proof as no active chemicals are used at all in its polymer coating.

    Gallery

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