Orora’s Helio direct-to-can digital printing continues to gain traction, with Pirate Life Brewing the latest to leverage the technology for a high-impact, limited-edition release.
Pirate Life Brewing has unveiled the latest Helio-enabled activation – a visually striking ‘disco ball’ can created to celebrate the brewer’s 11th birthday.
The limited-edition Mosaic Discotheque release is part of a growing series of Helio-powered collaborations, reinforcing the technology’s role in short-run, high-impact packaging.
Founded in 2014, Pirate Life has built its brand on bold, hop-forward beers and equally distinctive packaging. For this celebratory release, the team turned to Helio to elevate the visual and tactile impact of its 500ml cans.
“When we were planning our official birthday beer lineup for ’26, Mosaic was a shoo-in,” said Bianca Roworth, head of marketing at Pirate Life. “For this celebratory batch, we wanted to level up the packaging – that’s where Helio came in. We couldn’t be more stoked with the vivid and reflective results.”
Helio has lift-off
The ‘disco ball’ effect was achieved using Helio’s high-build digital printing capability, combining gloss and matte spot varnishes with a white-to-grey tonal blend to create a textured, reflective surface.
The result is a raised, dimensional finish that mirrors the layered flavour profile of the single-hop IPA, which features the Mosaic hop known for its tropical and resinous notes.
Helio’s high-build effect is created through a specialised coating process, cured using UV light to deliver a consistent, elevated layer across the can surface. The technology allows for intricate detailing, fast iteration, and short production runs – making it particularly suited to event-driven or limited-edition releases.
David Muzeen, pre-press supervisor at Orora’s Decoration Centre of Excellence (DCE), said early collaboration played a key role in achieving the final result.
“This project was a great example of the partnerships we value at the DCE. Pirate Life engaged with us at the concept stage, allowing us to optimise the artwork specifically for Helio and achieve the mirror ball effect.”
The DCE team produced multiple sample iterations, refining the finish before final production. The agility of digital can printing enabled rapid adjustments and approvals, highlighting one of Helio’s key advantages over conventional decoration methods.
Driving creative flexibility
For Pirate Life, the project builds on a long-standing partnership with Orora, with the brewer continuing to use cans as a core part of its brand expression.
Over the past five years, the two companies have collaborated across Pirate Life’s core range and limited releases, using packaging as a platform for storytelling and brand differentiation.
With Helio, that creative potential is expanding further – offering brand owners new ways to experiment with finishes, textures and designs without the constraints of traditional print processes.
As more brands explore digitally printed cans, Helio’s growing portfolio of activations signals a shift towards more agile, design-led packaging in the beverage sector.
