Aerosol Packaging – The Ultimate Guide

In aerosol containers, a propellant, generally liquefied gas under pressure, together with the product enclosed in the can. When you trigger the nozzle, it dispenses the contents as an aerosol.

Components of Aerosol Packaging

Aerosol Packaging
Aerosol Packaging

1. Container

Materials: Aluminum or steel are usually the cases you can use in the making of aerosol packages. Durability, rust resistance, and easy forming are the terms that can describe the suitability of these materials.

Design considerations: Make sure that the design of the container meets the safety measures. Thinks about the thickness, shape, pressure resistance, etc.

2. Valve System

Metered dose valves (MDVs): The valves release a particular volume of the product per actuation. Suitable for third-party personal care and pharmaceutical products.

Continuous spray valves: They are good for products that are similar to hairspray. These valves give a continuous and even flow of spray upon push. Efficient for covering larger areas.

Bag-on-valve (BOV) technology: This invention capability splits the product away from the fuel, hence isolating contact. Suitable for use in sensitive formulations and for shelf life-extending purposes.

3. Propellants

Hydrocarbon propellants (propane, butane): Environmentally friendly and common. They provide efficient dispensing and are economical.

Compressed air: Non-combustible and applicable to sensitive products. It offers a safe substitute, but you need to use an extra-size canister as it exerts lower pressure.

Nitrogen and nitrous oxide: However efficacious, they feature limited utilization because of fear of safety. For instance, nitrous oxide is potent but also dangerous.

4. Product Concentrate

Liquid, foam, gel: Select the concentrate according to the required form of products. Liquids to suit easy pouring, foams for greater surface area occupation, and gels for selective purposes.

Aerosol Packaging Components
Aerosol Packaging Components

Manufacturing Process of Aerosol Packaging – Step By Step

A. Canister Production

Material Preparation: Raw material preparation for canisters production is where you start.

Forming and Shaping: Form and shape the materials into the required canister using forming and shape processes.

Coating and Decoration: Coat canisters for protection and aesthetics. Make sure canisters meet quality specifications.

Quality Control: Carefully check every canister to ensure that they meet the standards specified.

B. Valve Installation

Assembly Process: Put the valves properly cartered in accordance with definite instructions.

Quality Assurance: Make rigorous quality inspections during valve installation for reliability and performance.

C. Propellant Filling

Safety Measures: Ensure safety by employing very strict guidelines to safeguard the worker as well as the aerosol product integrity.

Filling Techniques: Use filling precision to achieve the right product volume and pressure.

Quality Control: Routinely check and calibrate goods in filled canisters to promote uniform quality.

Types of Aerosol Packaging

Traditional Aerosol

  • Classical aerosol packaging includes cans fitted with a valve that dispenses aerosol content upon the press.
  • Suits products such as hairsprays, deodorants, insecticides, and so on. The product passes through the valve when you push the button as pressure from propellants drives the product.
  • User-friendly, and has controlled dispensing.
  • Propellants may affect the environment.
Traditional Aerosol Packaging
Traditional Aerosol Packaging

Bag-on-Valve (BOV):

  • In BOV, the bag, along with the valve placed inside the can. The bag contains the product and isolates it from the can.
  • Suitable for delicate goods, pharmaceuticals, and food.
  • Prolong’s shelf life decreases contamination risk.
Bag on valve [BOV]
Bag on valve [BOV]


  • The airless packaging relies on a pump mechanism.
  • Typical as in skincare, lotions, and serums.
  • The vacuum pump dispenses the product without creating air entry, hence reducing oxidation.
  • Preserves product integrity and precise dispensing.
  • It can be costlier to manufacture.
Airless Aerosol Packaging
Airless Aerosol Packaging

Foam Aerosols:

  • Foam aerosols deliver products formulated as foams and not as liquids or sprays.
  • Used in shaving creams, cleansers, and some hair products.
  • Creates a foam at the nozzle during dispensing upon mixing of the liquid and the gas.
  • Improved coverage and enhanced user experience.
  • Specific formulations limit the widespread applications.

Advantages of Aerosol Packaging



You can benefit from using aerosol packaging due to its straightforward mechanism of pressing and spraying. It is also fast, saves you time and energy to spare you with all this trouble.

Preservation of Product Integrity:

You protect your products from the outside world, therefore assuring they remain fresh and, most importantly, quality. Among the packaging methods is aerosol packaging, which acts as a barrier, ensuring the integrity of the content.

Uniform Dispensing:

You can trust fixed product dissemination. Aerosols ensure precision spray with uniformity, and you can also control the amount of your spray every time.

Metered Dosage:

Enjoy precision in application. Aerosol ensures exact quantification every time, minimizing wastage and maximizing efficiency.

Reduced Waste:

You reduce needless product wastage, thereby supporting sustainability. Using aerosol packaging reduces wastage since using only what is required, and this, in turn, helps in reducing the total environmental impact in the long run.


Carry your best product wherever you are. Compact and travel-friendly, aerosols effortlessly blend into your lifestyle.

Protection Against Contamination:

Your products remain clean and untainted. Aerosol packaging prevents the ingress of external contaminants and thus keeps the contents inside it pure.

Versatility in Formulation:

Various formulations. Aerosol packaging is conducive to all forms of product consistencies ranging from foams to liquids. Thereby enabling diverse applications.

Key Challenges when Packaging Aerosols

Environmental Concerns:

  • You have to discuss the ecological footprint of aerosol packaging.
  • Think of the adverse effects often brought by propellants and VOCs.
  • Discover green alternatives to minimize your carbon footprint.

Flammability and Safety Risks:

  • Aerosols are highly flammable and therefore, you must offer the greatest attention to safety concerns.
  • Provide adequate ventilation and storage to reduce fire hazards.
  • Train workers assigned to safety guidelines and emergency response measures.

Limited Shelf Life for Some Products:

  • Be aware that some of the aerosol products may only have a short expiry date.
  • Make sure that the item has not passed its expiration date so as not to use expired products.
  • Put in practice flawless inventory management to reduce the level of waste.

Recycling Challenges:

  • Know about the difficulties in recycling aerosol packaging.
  • Reflect on problems associated with diverse materials such as metal and plastic.
  • Take some innovative methods of recycling or make sure to support recycling programs in your area.

Applications of Aerosol Packaging

Household Products:

Cleaning Sprays:

You get the benefits of aerosol packaging in cleaning sprays that are applied easily and on specific surfaces. It enables you to spray the cleaner uniformly to tight corners automatically.

Air Fresheners:

Your aerosol package ascertains a light mist to give a nice scent protruding through the house. You have instantaneous and steady diffusion of the scent, thus improving the environment.

Insect Repellents:

The aerosol packaging for insect repellents facilitates widespread use on your skin, clothes or other surfaces. You are adequately protected from pests with just a spray.

Personal Care Products:


The use of aerosol packaging allows for quick and uniform distribution of deodorant, thus providing full coverage. A quick application makes the whole process of freshness long-lasting.

Hair Sprays:

The packaging of aerosol in hair spray satisfies fine shortfall options for effective styling. It will keep your style in place and lightweight, evenly distributed hold.

Shaving Creams:

With shaving creams, the aerosol packaging allows the product to be easily smoothed with less friction. You get a good shave with an even lotion lather.

Industrial and Automotive Applications:


Aerosol packaging allows the lubrication of heated objects, for example, industrial machinery or automotive parts, more precisely. Availability convenience to the functionality of certain elements is highly applicable.

Paints and Coatings:

The aerosol packaging in paints and coatings renders uniform application on surfaces in a loving manner. You get finer and even result with little labor.

Automotive Products:

It is especially important for automotive products such as rust inhibitors or brake cleaners, which require aerosol packaging. Their convenient and efficient application guarantees the long-term and excellent functioning of your vehicle components.

Considerations For Choosing The Right Aerosol Packaging

Environmental Impact:

  • Propellants: Select aerosols that contain environment-friendly fuels in order to decrease destructive effects on nature.
  • Recyclability: Go for recyclable packaging materials.
  • Biodegradability: Consider biodegradable materials to enable a part of a greener footprint.

Safety Measures:

  • Flammability: Make the aerosol non-flammable or minimally flammable.
  • Pressure Regulation: Look for stable pressure regulation systems to prevent occurrences.
  • Valve Integrity: Ensure the valve system is reliable a secure to reduce leaks.

Regulatory Compliance:

  • Product Classification: Make sure that the product falls under the right regulatory classification.
  • Safety Standards: Follow safety requirements to comply with legal demands.

Consumer Safety:

  • User Instructions: Elaborate on use instructions for safety.
  • Child-Resistant Packaging: In the household, carry a note of child-resistant features to increase safety.

Quality Control:

  • Manufacturing Processes: Introduce strict manufacturing practices to ensure quality.
  • Testing Protocols: Testing of the product to the satisfaction that the safety as well as quality standards are met.


  • Material Selection: Select green materials to make a small footprint.
  • Product Lifecycle: Adopt a Holistic approach, that is, the whole life cycle of the product, from manufacture until the point of disposal.

Chemical Compatibility:

  • Check to ensure that the packaging materials are not reactive with the contents to prevent incompatibilities in the contents.

Dispensing Control:

  • Metered Dosage: A metered dispensing system ensures accurate and uniform dosage.
  • Spray Patterns: Choose the adjustable spray patterns that increase the user’s experience and therefore, simple production needs for control.

For all your packaging solutions, LOM has custom solutions for every product. Whether you are looking for liquid filling machines, powder fillers, or any other packaging solutions, we are your trusted partner.

More Resources:

Aerosol Containers – Source: BRITANNICA

Principle of Filling Machines – Source: LOM

VFFS vs HFFS – Source: LOM

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