Helio delivers high-build impact for Pirate Life cans
Orora’s Helio direct-to-can digital printing technology has been deployed for Pirate Life Brewing’s latest limited-edition release, Mosaic Discotheque, showcasing the system’s ability to deliver high-build, tactile finishes on aluminium cans.
The project forms part of a growing series of Helio-enabled activations, highlighting the technology’s flexibility for short-run, design-driven applications.
Designed to celebrate Pirate Life’s 11th birthday, the 500ml can features a ‘disco ball’ motif created using a combination of gloss and matte spot varnishes layered over a white-to-grey tonal blend.
The effect was achieved using Helio’s high-build coating capability, where a specialised coating is applied via a dedicated print unit and cured with UV light. This allows for thicker ink deposition and a raised, dimensional surface finish.
The result is a textured, reflective effect that would be difficult to achieve using conventional can decoration processes.
David Muzeen, pre-press supervisor at Orora’s Decoration Centre of Excellence, said early engagement was critical to achieving the final outcome.
“Pirate Life involved us at the concept stage so we could optimise the artwork for Helio and achieve the mirror ball effect. We produced sample cans, refined the finish, and quickly iterated based on feedback.”
The digital workflow enabled rapid file adjustments and re-sampling, demonstrating Helio’s advantage in reducing lead times and supporting agile production.
Digital enables iteration
For brand owners, Helio offers the ability to test and refine designs without the constraints of traditional print methods, including lower minimum order quantities and faster turnaround times.
Pirate Life’s head of marketing, Bianca Roworth, said the technology enabled the team to push the creative boundaries of the design.
“We wanted to level up the packaging for this release, and Helio allowed us to achieve a vivid, reflective finish that enhances the design.”
As digital decoration continues to evolve, Helio is positioning itself as a viable solution for premium, short-run applications where visual impact and production flexibility are key.
