Beverage cans have a long‑standing limitation: once opened, they cannot be securely closed again. The inability to reseal often leads to spilled drinks, partially consumed beverages being thrown away, and unnecessary loss of the energy and CO₂ used to produce and distribute the product. To address this problem, XOLUTION Germany GmbH, a developer and producer of resealable solutions for the beverage can industry, created a patented closure called the XO Relock System that converts a standard aluminum can into a fully leak‑proof, resealable package without changing the basic can format.
XO Relock is designed to retain the key advantages of aluminum cans, such as low weight, robustness, and recyclability, while fitting into existing industrial processes and supporting ongoing reductions in material use and environmental impact. This combination of functionality and environmental performance has earned XOLUTION the Environmental award in the Resealable Cans category in the 2025 Packaging Gateway Excellence Awards.
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Resealable cans cut product waste and CO₂
Most of a beverage’s environmental footprint comes from producing, filling, chilling, and transporting the liquid, not from the packaging itself. However, when drinks are spilled or partly consumed and then thrown away, that embedded energy and CO₂ is lost. The XO Relock System helps prevent this loss by allowing an opened can to be closed securely and used again later. Its resealable, leak‑proof design, operable with one hand, reduces losses from unfinished drinks and accidental spills, especially with larger cans.
The closure is gas‑tight, which means it keeps carbonation and flavor inside the can while limiting oxygen entry. The latest generation of the closure reduces oxygen ingress to around 50ppm over six months, helping to maintain taste and carbonation for longer and slowing quality loss in normal use. This gives consumers a clear reason to save the remaining contents rather than discard them. Because most lifecycle emissions are linked to the liquid, even small reductions in partial‑consumption waste can offer a meaningful environmental gain.
Hygiene is another advantage. By covering the mouthpiece and shielding the drinking area from dust, dirt, insects, and other contaminants, the XO closure lowers the chance that consumers will discard a drink for safety reasons. The tamper‑evident band breaks on first opening and then remains attached, disappearing behind the pull tab when relocked. This shows whether the can has been opened before and avoids loose plastic pieces.
Making aluminum cans a stronger alternative to PET
Aluminum cans already perform well in terms of recycling rates and closed‑loop potential. However, the lack of resealability has limited their use in situations where PET bottles and other resealable formats are preferred, such as on‑the‑go or multi‑serve consumption. XO Relock closes much of this gap and enables brands to use aluminum cans in more of these occasions.
A resealable, leak‑proof closure makes it easier for consumers to carry cans in bags, cars, or backpacks with a lower risk of spills. Partial consumption is more common with beverages such as energy and functional drinks, wellness beverages, craft products, and many ready‑to‑drink formats. Packing such products in resealable cans reduces both environmental and economic losses from waste.
The closure uses fully recyclable, BPA‑non‑intent plastic and remains permanently attached to the can end, so there are no separate caps or rings that might become litter or complicate sorting. The tamper‑evident band also stays connected after breaking. This design is intended to work with established aluminum recycling systems and avoid new detached components in the waste stream.
Scalable integration and focused footprint reduction
Another advantage of the XO Relock System is its fit with current industrial infrastructure. The closure is based on industry‑standard can shell platforms and works with major can profiles and diameters already in use. According to XOLUTION, no changes to filling equipment are required, and there is no need to adjust chucks or rolls in the seamer for similar shell styles. This allows resealable cans to be introduced with minimal disruption to existing lines and limits the need for major new investments.
XOLUTION has also worked to reduce material use in the closure. The current design is modular, fully recyclable, and adaptable to common can sizes from 150 ml to 750 ml. The next generation, XO 2.5, planned for 2026, lowers plastic content to around 2.9 grams per closure and is designed to handle filling temperatures up to 85°C with nitrogen and products that are sensitive to oxygen.
The closure supports features such as laminar liquid flow for smoother drinking and a tamper‑evident, child‑resistant configuration that aligns with safety and hygiene requirements. With more than 500 million units produced and used by international beverage manufacturers, the XO Relock System is already established in commercial markets.
“What an honor and great appreciation for our efforts towards an eco-friendly footprint. This is a real proof for our tireless commitment to sustainability and innovative packaging solutions and recognition, that turning the beverage can´s weakness – non-resealability – into a strength.”
– Marc von Rettberg, CEO
Company Profile
XOLUTION Germany GmbH is a Munich, Germany-based company. It develops, produces, and supplies resealable solutions for the beverage can industry. XO has a fully integrated organization with responsibilities in the areas of R&D, production, laboratory, business development, sales, marketing, and finance. It aims to bridge the gap between traditional drinking cans and the demands of the “generation on-the-go“ – sustainable. It presents drinking products that are tailored to meet the requirements of increasingly mobile lifestyles. The revolutionary XO Resealable Can System makes drinks available at any time – always fresh, always safe! It’s the Relock Revolution and will change the way one drinks!
Contact Details
Leonie Bechtoldt
E-mail: info@xolution.com
Links
Website: https://xolution.com/
