According to the 2024 global energy drink market research, 500ml can size (66mm diameter × 122mm height) accounts for 35% of the category’s packaging, but whether it is suitable needs to be taken into account together with functions and usage occasions. Red Bull is a case in point. The grip force required for handling one 250ml can (dia. 53mm×h. 115mm) is 7.8 Newtons, and for handling a 500ml can, with the increase of volume, the grip force becomes 10.2 Newtons (biomechanical test results). For the age group of consumers from 18 to 35 years, 43% find that it is “not easy to handle with one hand.”. However, Magic Claw Energy Drink has driven a 19% increase in sales in the North American market by optimizing the diameter-to-height ratio of the can (H/D=1.85→2.0), reducing the diameter of the 500ml can to 61mm and the grip force to 8.5 Newtons (2023 statistics).
In terms of production efficiency, the aluminum consumption of 500ml can sizes is 13.2 grams per can (regular can), while the slim shape (58mm diameter ×140mm height) can reduce the use of aluminum by 9.8% (11.9 grams per can). However, the expense of stamping die development has increased by 25% (approximately 120,000 US dollars per set). Ab InBev’s 2023 estimates show that the expense of altering a slim can line having a capacity of 48,000 cans per hour is 2.2 million US dollars. However, after large-scale production (≥ 100 million cans), the cost per can is reduced by 4.6% (0.108→0.103 US dollars). On the other hand, the conventional 500ml tank line transformation expense is only 450,000 US dollars, but the aluminum material waste rate is 2.3% higher (waste recycling statistics).
Research on consumer behavior indicates that 500ml can sizes have a higher acceptance rate under dynamic conditions. Nielsen statistics show that the sales share of 500ml energy drinks in the gym channel is as much as 58% (32% through the convenience store channel), since their volume is in line with the average water requirement of 60 minutes of intense training (450-550ml). However, for the in-vehicle scenario, compatibility of cups with diameters exceeding 65mm and cup holders is only 67% (92% for thin cans), so Coca-Cola Europe has adapted some of its 500ml lines to thin cans, resulting in a 27% increase in in-vehicle channel sales (2023 figures).
Regulation and sustainability pressures drive change. EU’s “Packaging and Packaging Waste Regulation” (PPWR 2025) requires recyclable content in beverage cans to be ≥ 30%. Slim cans’ carbon footprint per can, with 9.8% less weight, has decreased from 113 grams of CO₂ to 102 grams of CO₂ (a 9.7% decrease). Carlsberg group, converting to slim tank two aluminum use by 11200 tons, but also need to adjust recycling sorting speed from 3.2 m/SEC – 2.8 m/s, to avoid sorting error rate from 1.1% to 2.7%.
The actual case verification value: In 2022, Red Bull Thailand launched a 500ml can. Due to the lack of optimization of the grip design, the return rate was 3.4% (the industry average was 1.2%). The following year, after improving to a 61mm diameter version, the return rate dropped to 0.9%, and sales increased by 15%. Data show that 500ml can dimensions need to be iterated by combining ergonomics and scene adaptation in order to maximize commercial benefits.
