Spray Can Filling and Packaging


aerosol filling machine

Daily chemicals such as deodorants, polishes, air fresheners, and paints are all packed in aerosol cans for your convenience; thanks to spray can filling. Aerosol dispensers typically come in two major varieties: misters and cans. Aerosol packaging made use of chlorofluorocarbons (CFCs) in bygone days proved harmful to our ozone layer.

Nevertheless, after the ban, aerosol spray makers shifted to using alternatives that do not contribute to ozone depletion. Propane and butane were among the alternative chemicals used as propellants by aerosol spray makers. While these items do not harm the ozone layer, they do have significant drawbacks. For instance, they pose health risks when inhaled and are very combustible.

We will cover phases of the aerosol product life cycle, including production, packaging, and advantages.

Aerosol: What is it?

The gaseous or liquid cloud that comes out of an aerosol can is an aerosol. There are many solid particles suspended in the gas, creating a thin mist of liquid. Because they consist of water droplets dispersed across a wide volume of air, kettle steam is an example of aerosols.

While both smoke and heated, rising air are aerosols, the difference is that smoke also includes solid fragments of unburned carbon. The hazy mist that rises to the top of the flame of a candle is another kind of aerosol. Composed of water vapor and unburned carbon, it disperses throughout our air.

Aerosols’ Cold Sensation

Because they evaporate quickly, aerosols make you feel cold when you spray them on. As an example, at room temperature, aerosols such as deodorants and perfume misters evaporate. Upon releasing the nozzle, the product quickly evaporates.

A significant amount of energy breaks down the molecules of the liquid aerosol filled with gas. Afterward, the liquid absorbs the energy and cools down. Furthermore, evaporative cooling causes you to feel chilly when you inhale aerosols onto the skin.

To convert the liquid spray to gas, you’ll need to use the energy that your body produces. The can’s inside and outside are both cooled through evaporative cooling, which happens when the pressure within the can is reduced by spraying.

Can Manufacturing for Aerosol Sprays

Manufacturers of aerosol sprays use a variety of design approaches. The metals used by many companies are capable of securely holding gases and liquids under pressure. Coating the thin steel metal sheets creates most home aerosols and protects them against corrosion and any reactions that may occur when spray can filling.

Experts create tinplate by covering metal surfaces with tin and then electroplating them. Cans of aerosol spray are made impermeable by shaping a tinplate into a cylinder and then welding its top and bottom. Most aerosol spray makers now use plastic liners instead of tin to keep their products more environmentally friendly.

In addition to being recyclable, polymers such as polymer are less expensive. One method that some manufacturers use to create their cans is to take a little lump of aluminum and shape it into a cylinder by pressing it through a die. For the purpose of labeling and instruction writing, they apply the offset printing technique.

Glass aerosol cans are also available. Since it is impervious to corrosion and has no reaction with the aerosol filling, glass is, in theory, the perfect material. Glass shattering under pressure or impact is a disappointing reality.

How Aerosol Cans Work

Because it is not simple to pressurize liquids, you should not try to use an aerosol can with liquid paint. Gas pressurization, fortunately, is not hard at all. This is how aerosol cans have two parts: the product you want to spray and a propellant to make it spray out over the air.

Shake the can vigorously before use to combine the propellant with the liquid solution. Liquid gaseous propellants retain their liquid state even after being compressed to pressures over their boiling point or kept at temperatures above their melting point. Because it is a liquid when left at room temperature, the producer fills the can with the product and then seals it.

And then, after closing the container, they have to pump the propellant at extreme pressure. Because there is no space for a propellant to expand into gas when kept under high enough pressure, it will stay in its liquid state.

Aerosol Mist

A mechanism in aerosol cans is responsible for transforming the aerosol contents into a fine, uniform mist. When you push the can button to spray an aerosol, such as a spray, the manufacturer uses a pump or compressor to compress the contents into the container, ensuring an equitable distribution of the substance.

Keep the aerosol filling pressure higher than the ambient air so that it will rush out when you click the top button. By releasing some force on the liquid propellant, the valve opens as soon as you press the button. This causes it to boil, which releases the particles and causes a gaseous layer to build on top of the container.

A pressured layer drives the propellant and liquid product to the nozzle. In order to create a fine mist, the propellant and product in some aerosol cans are mixed using ball bearings. The propellant is transformed into a fine mist when the liquid goes past the nozzle.

Can designs include a foaming mechanism within the spray can filling, which is created as the propellant evaporates. How consistent the administered product is depends on a number of things. Considerations such as product-to-propellant proportion, propellant pressure, the chemical composition of the aerosol filling, and the dimensions of the propellant and valve mechanism.

Spray Can Filling and Packaging

Aerosol Spray Production

When making their aerosol spray, respectable companies follow all applicable regulations, quality requirements, and environmental protocols. To ensure the highest possible product quality, certain requirements are essential. When spray can filling, most producers use this process:

Gathering Basic Supplies  

Companies in the manufacturing sector rely on dependable suppliers for their raw materials. As a result, their goods are designed with top-notch components that provide real-world benefits. The top producers of aerosol sprays also provide their customers with a comprehensive inventory of raw ingredients that meet or exceed all applicable requirements, including those of the food and other sectors.

Development of Products

You will start the product development step after gathering all of the supplies you need. Professional aerosol producers have extensive knowledge in creating cutting-edge goods. The ever-changing demands of consumers and the trends in the industry are no match for them.


The production process is set by the specifications that the spray can filling must meet. Further, manufacturers will have access to a quality handbook that they may use to verify intermediate controls such as soak, pressures, production, and measurements.


aerosol can filling machine for sale

Spray Can Filling with Aerosol Filling Machine


Quality Control of the Final Product

Manufacturers of aerosol sprays must do an additional quality control check on the finished goods after palletization to ensure that all critical aspects, including yield, traceability, security, and others, are accurate. To decide either to accept or reject a product, the procedure examines for defects. If items are rejected, manufacturers will fix them according to their processes after registering the problems.

Packaging Aerosols

Various culinary, cosmetic, cleaning, pharmaceutical, and medical product brands have opted to put their products in aerosol cans. Certain goods may only be suitable for aerosol packing. People use aerosols all around their homes, yards, and even on the go. Aerosol cans include a wide variety of common household items, such as deodorant, hairspray, fragrances, cleaning disinfection, painted surfaces, and lubricant.

The aerosol filling, which is often a mist or foam, is dispensed from aerosol cans using aluminum cylinders or spray bottles. Even though aerosol goods are still available, American-made and -sold ones do not include any chemicals that harm the ozone barrier.

Manufacturers now use propellants like hydrocarbons and nitrous oxide, which impact the carbon footprint negatively. These products contribute to ground-level ozone due to the hydrocarbons and compressed gasses that produce volatile organic compounds.

In addition, the cans of aerosol sprays are recyclable as many of these products include at least 25% recycled materials. So, the use of aerosols is good for the environment. Also, tampering is difficult to detect with aerosol packing, and once it happens, you’ll know it is. Because of these security measures, they are perfect for a lot of people.

Aerosol Packaging Advantages

Aerosol packaging offers a plethora of advantages. Here are some bases why aerosol packaging is an alternative you should consider:

  • Gives consumers authority: An aerosol can’s main selling point is the precise control it gives the user over the spray’s output with the touch of a button. This leads to less waste and leakage and better product use.
  • Hygienic: You don’t even need to touch the container to use the aerosol contents. Hence, it is secure to exchange personal items. In addition, the cans hinder the spread of pathogens, filth, and contaminated products.
  • Easy to Use: One of the main reasons people buy aerosol cans is because of this. Aiming and pressing the can with only one finger makes dispensing the product a breeze.
  • Safeness: There is less chance of leakage, damage, or spilling when you seal aerosol sprays hermetically. The seal also serves as an effective deterrent against exploitation.
  • Ease: Being spill-proof and preventing applicators and containers from mixing is an additional advantage of aerosol packing. Not only that, but the aerosol cans themselves can hold refill items for quite some time.
  • Value for money: The aerosol can optimize the spray’s efficacy by regulating the spray’s concentration, spraying style, volume, and particle size. Another benefit is that the container keeps the aerosol contents, such as paint, safe. By preventing evaporation, they increase the storage life.
  • Availability: Products like pesticide sprays, shave creams, inhalers, and countless more have been made possible by aerosol packaging.
  • Reusable: Aluminum, the material used to make aerosol cans, is easily recyclable.

Tips for Choosing the Best Aerosol Containers


Manufacturers of aerosol sprays must take product specifics into account when deciding on container dimensions, color schemes, and other qualities. The standard dimensions for aerosol cans are a height of 70-265 mm and a diameter of 35-76 mm.

Most cans have a one-inch opening at the top. Cans are available in either white or clear, depending on your base coat color. After settling on a suitable size and color, you may start planning the can decor that will complement your product and brand.

As far as finishes go, you have the choice of soft-touch, high-gloss, or brushed aluminum. Plus, there are experts who like metallic and textured patterns. The shape of the package will give the can’s shoulder style. It can be flat, round, oval, conical, or bullet shape.

Additionally, you must consider Prop 65 and BPA regulations for producing aerosol sprays. Depending on the country of distribution, you must consider liner options that comply with BPA regulations. As an example, BPA NI liners are necessary for food goods as they are free of BPA.

As a last consideration, aerosol manufacturers must think about the pressure necessary to release the aerosol filling via the valve. To guarantee accurate dispensing, the product filler should specify the precise pressure resistance.

Bag-On-Valve Aerosol Packaging

Aerosol cans wouldn’t be complete without a valve, which enables precise control over the spray’s release. It sits atop the container, under the button that needs pressing.

A spring stops the button from staying open. When you press the button, the valve opens, releasing the aerosol filling from the can by lowering the internal pressure. Pressing and releasing the button closes the valve.

The BOV system is a component of modern aerosol canisters. By instigating a physical separation between the aerosol filling and the propellant, the method ensures that the product remains entirely pure inside the container.

While aerosol cans with BOV systems resemble conventional aluminum cans in appearance, they function differently. When the valve is pressed in a BOV system, nitrogen and air are introduced into the space between the container and the bag. The end consequence is that you’ll never mix the product with the propellant.

To fill BOV systems, manufacturers may use liquids or viscous items that are thick enough to flow through the valves. The majority of the same sectors have BOV cans for consumers to choose from. There are several advantages to BOV systems beyond those of standard aerosol products:

  • Within the container, the propellant and product are completely separated.
  • A strong barrier that keeps oxygen out of the can.
  • Uses non-flammable propellants to prevent container fires.
Scroll to Top