Manufacturing guide · Beverages
Carbonated soft drinks in cans contract manufacturing in India
Most Indian canners want a minimum of 25,000–1 lac cans per SKU to justify a changeover on a carbonation and filling line, with a 250 ml can landing around ₹14–24 ex-factory depending on juice content and sweetener system. Expect 6–10 weeks from a signed-off formulation and can artwork to the first filled pallet, and an FSSAI licence is non-negotiable before any batch leaves the plant.
Key facts
| Typical MOQ | 25,000–1 lac cans per SKU (lower for a single flavour trial run on a shared line) |
|---|---|
| Typical pack sizes | 150 ml, 250 ml, 300 ml sleek and standard cans; multipacks of 4/6 |
| Indicative cost per unit | ₹14–24 per 250 ml can, ex-factory |
| What the cost covers | Includes syrup/concentrate, CO2, can body and end, filling and seaming; excludes GST, freight, outer shipper beyond primary pack, and brand margin |
| Lead time, brief to first batch | 6–10 weeks from approved formulation and can graphics to first batch |
| Key licences and certifications | FSSAI manufacturing licence; product must meet FSSAI standards for carbonated beverages and Legal Metrology labelling |
| Typical shelf life | 9–12 months unopened, stored away from heat to limit carbonation loss |
| Common formats | Aluminium cans (sleek, standard, slim), occasional PET for larger pack sizes |
How it is made
Syrup preparation
Sugar or sweetener blend, acidulant, flavour and colour are batched and filtered to a set Brix before carbonation.
Water treatment
Treated water is de-aerated and chilled so it can hold carbon dioxide without excess foaming at the filler.
Carbonation and filling
Syrup and carbonated water are proportioned in-line and filled into cans under counter-pressure to lock in CO2 volumes.
Can seaming
A double-seamer crimps the lid onto the filled can; seam tightness is checked by teardown on a sample schedule.
Date coding and casing
Cans are coded, dried, and packed into shrink-wrapped trays or shipper cartons for dispatch.
What drives the cost
raises cost
CO2 volumes and carbonation level
Higher carbonation needs tighter seam specs and slower line speeds, adding to per-can cost.
raises cost
Real fruit juice or natural flavour content
Natural flavour systems and juice concentrate cost more than synthetic flavour-and-colour blends.
raises cost
Can gauge and sleek format
Thinner-gauge or sleek cans need specific tooling and often carry a packaging premium over standard cans.
lowers cost
Order volume per flavour
Longer runs amortise the changeover and cleaning time between SKUs on a shared carbonation line.
depends
Sweetener choice
Sugar is cheaper per kg but zero-calorie blends can lower syrup cost per litre depending on the blend used.
Common mistakes first-time brands make
Ignoring can supply lead time
Printed cans are ordered separately from the filler and can take 4–6 weeks on their own; this is often the real bottleneck, not the filling line.
Under-specifying carbonation volumes
A vague 'well carbonated' brief leads to inconsistent fizz between batches; specify CO2 volumes in the formulation sheet.
Skipping seam audits
Weak double seams cause leakers in transit; ask for seam teardown data, not just a visual check, on every shift.
Choosing a manufacturer for carbonated soft drinks in cans
Carbonation and filling capability
Confirm the plant runs true carbonated beverage fillers, not just still PET lines retrofitted for cans.
Certifications
Look for FSSAI licence validity, and ISO 22000 or FSSC 22000 as a sign of documented process control.
Can line capacity and changeover
Ask how many SKU changeovers the line handles per week and what the minimum run length is to avoid excess scrap.
Sampling and shelf trials
A manufacturer should run a small carbonation and taste trial batch before committing to the full MOQ.
Frequently asked questions
- Can I start with a smaller MOQ than 25,000 cans?
- Some canners offer trial runs of 10,000–15,000 cans on shared slots, usually at a higher per-can cost. This is useful for market testing before committing to full MOQ.
- Do I need my own can design tooling?
- No, printed cans are usually sourced from a can-maker on your behalf or directly, using your approved artwork film; no separate tooling investment is needed for standard can diameters.
- How is shelf life affected by storage?
- Carbonation loss accelerates in heat, so cans stored above typical warehouse temperatures for long periods can taste flat before the printed date; cool, dry storage preserves the stated shelf life.
- What causes can swelling in the field?
- Swelling usually points to microbial contamination from inadequate sanitation or under-pasteurised syrup; a manufacturer with validated CIP (clean-in-place) protocols reduces this risk.
- Can flavour and colour be adjusted after the first batch?
- Yes, most contract manufacturers allow a formulation tweak after the first trial batch, though a second small trial run is recommended before scaling to full MOQ.
How BrandForge helps
BrandForge takes your CSD brief and matches it blind against verified can-line manufacturers who already run your carbonation and sweetener profile, so you are not paying to discover capability gaps. Partner identities are revealed only once both sides approve the fit, and a success manager tracks the trial batch through to first commercial run.