Like I said I do not know the answers to these questions, I am only describing a possible scenario. Someone would need to research the best solutions. Aluminum does use a lot of energy to refine.

I have seen 24 ounce aluminum cans for beer though so we could see large American sodas in big cans. Not resealable though.

I think if we are willing to commit to building infrastructure, there is a lot to like about washing glass bottles. In at least one of the Nordic countries they require the use of a standard glass bottle with paper labels that wash off. With this, bottles can be returned to the closest bottler even if it’s a different brand. This keeps travel low. If bottling plants are near population centers the carbon cost of bottle transportation can be kept low.