Simulation‑Guided Downgauging and Process Optimization of Recycled‑Content Aluminum Trays

EcoTray addresses these limitations by developing a high-fidelity finite element simulation framework that integrates experimentally measured material behavior and advanced friction models. The project focuses on targeted mechanical testing to characterize the forming limits of aluminum alloys with recycled content. In parallel, it incorporates realistic, pressure- and velocity-dependent friction models to accurately represent the tribological behavior under actual forming conditions. By unifying these data-driven insights into a single simulation and design platform, EcoTray will empower AMCOR to shift towards the use of thinner, recycled-content aluminum trays while maintaining product integrity and process reliability.

This transition is expected to significantly reduce scrap rates, eliminate much of the costly physical prototyping phase, and accelerate the qualification of sustainable materials. The EcoTray framework not only enhances process predictability and tooling lifespan but also directly supports decarbonization objectives by minimizing raw material consumption and associated CO₂ emissions. Ultimately, this project enables a scalable, economically viable pathway to low-carbon tray manufacturing that aligns with both regulatory expectations and corporate sustainability targets.