UNDERSTANDING AND MITIGATING CORROSION IN ALUMINUM BEVERAGE CANS
Corrosion in aluminum beverage cans is a growing challenge as more diverse and corrosive beverages are packaged in aluminum cans. Although polymer liners are designed to prevent direct contact between beverage and metal, recent evidence shows that components such as low pH, high chloride content, sulfur dioxide, etc. can permeate, degrade, and compromise liner integrity. These failures can lead to increased dissolved aluminum, leaking cans, and formation of hydrogen sulfide (in beverages containing sulfites). Across various beverages, substantial variability in corrosion outcomes is observed, highlighting the difficultly in predicting compatibility between beverage and can liner from beverage components. 10 wines (6 white, 2 red, 2 rosé) were canned in BPA-epoxy, BPA-NI epoxy, and acrylic coated cans and stored for 1, 2, 4, and 8 months at 20 °C. H2S, dissolved aluminum, and visible corrosion were assessed after each time point. H2S was found to correlate with visible corrosion but not dissolved aluminum. BPA-epoxy and BPA-NI epoxy performed similarly, while acrylic was found to not be a suitable liner for holding wines. Among wine chemistry, molecular SO2 was best correlated to H2S production. An accelerated aging test was also established using lined 1x5 cm can coupons, enabling prediction of long-term H2S within 3 – 14 days of storage at 50 °C. Accelerated aging with bare aluminum showed no correlation with long-term aging in real cans, illustrating the necessity of evaluating corrosion within coated systems. Corrosion was also examined in a high-chloride beverage, where pitting corrosion occurred even in BPA-NI epoxy-lined cans. The possibility of using food-safe anti-corrosives to address this problem was explored. Low-molecular-weight chitosan (<5 kDa) emerged as an effective inhibitor, decreasing aluminum dissolution more than ten-fold and eliminating pinhole formation during extended storage. Electrochemical impedance spectroscopy (EIS) confirmed improvements in liner barrier properties, and testing of multiple commercial chitosan sources revealed that anti-corrosive efficacy was limited to low-molecular-weight preparations (<5 kDa), though not all low-molecular-weight chitosan preparations were effective. These findings establish chitosan as the first known food-grade additive capable of materially enhancing corrosion resistance in lined aluminum cans. Within high-electrolyte beverages, it was observed that two beverages with nearly identical composition (Cucumber Lime and Watermelon flavored Gatorlyte), were quite different in terms of corrosivity when coated liners were measured with EIS, despite being identically corrosive to bare aluminum. It was hypothesized that certain beverage additives – such as flavors, flavor carriers, colorants, or organic acids – could unexpectedly accelerate corrosion by altering liner permeability. When these beverage additives were used to adulterate a mildly (pH 3.6, 1759 mg/L Cl-) and moderately (pH 3, 3000 mg/L Cl-) corrosive beverage, additives studied decreased barrier properties in 13 out of 15 treatments for the moderately corrosive beverage, while only two additives decreased barrier properties for the mildly corrosive beverage. Several additives produced non-linear effects, in which the lowest concentrations caused the greatest decline in impedance. Overall, these results demonstrate that beverage-liner interactions could be the most important consideration for corrosion in aluminum beverage cans (instead of beverage-metal interactions). This work advances the understanding of aluminum beverage can corrosion, demonstrates the value (and limitations) of accelerated aging, and introduces a novel food-grade anti-corrosive as an approach capable of extending the shelf life of hard-to-hold beverages in aluminum cans. These findings provide practical guidance for beverage producers of canned products and can manufacturers seeking to ensure product stability.