---
title: Manufacturing Process, Technical Principles, and Key Procurement Points for Aerosol Cans
description: In the field of cosmetic packaging, aerosol cans are widely used in various products due to their convenient application, excellent sealing, controlled dosage, and unique user experience (such as spray,
url: https://www.dmcostech.com/blog/manufacturing-process-technical-principles-and-key-procurement-points-for-aerosol-cans
markdown_url: https://www.dmcostech.com/blog/manufacturing-process-technical-principles-and-key-procurement-points-for-aerosol-cans.md
type: post
slug: manufacturing-process-technical-principles-and-key-procurement-points-for-aerosol-cans
author: admin
published: 2025-09-02T09:30:10Z
modified: 2026-04-17T13:59:59Z
language: en-US
taxonomies:
  category:
    - Packing materials
word_count: 2558
tokens: 5677
---

# Manufacturing Process, Technical Principles, and Key Procurement Points for Aerosol Cans

In the field of cosmetic packaging, aerosol cans are widely used in various products due to their convenient application, excellent sealing, controlled dosage, and unique user experience (such as spray, foam, or mousse forms). This article will systematically analyze their material properties, forming processes, technical principles, key quality control points, and cost structure.

1.  Main Materials for Aerosol Cans

Manufacturing Process, Technical Principles, and Key Procurement Points for Aerosol Cans 1

1. Aluminum Cans:

Mainstream Choice: Holds the absolute dominant position in the cosmetic aerosol can market (especially for mid-to-high-end products).

Advantages:

   Lightweight:Reduces transportation costs.

   Seamless:Formed by impact extrusion and drawing, the can body is seamless, offering excellent sealing and high aesthetic appeal.

       Corrosion Resistant: The inner wall can be coated with various high-performance coatings (see below) to resist corrosion from the contents and propellant.

       Good Malleability: Easily processed into various shapes (straight, waisted, irregular) and sizes.

       High Recyclability: High recycling rate, aligns with environmental trends.

       Good Surface Decoration: Suitable for various printing processes (offset, silk screen, hot stamping, etc.), presenting a premium texture.

   Structure: Typically consists of a can body, top cap (for valve mounting), and bottom cap (or formed integrally through drawing).

   Coatings:

       Inner Coating: Crucial! Prevents reaction between the contents/propellant and the aluminum, ensuring product stability and safety. Common coatings:

           Epoxy-Phenolic Resin: Strong versatility, good corrosion resistance.

           PVDF (Polyvinylidene Fluoride): Excellent resistance to strong solvents, high temperature, and barrier properties; used for high-demand products (e.g., sprays containing high concentrations of alcohol, strong solvents, or active ingredients).

           Epoxy Resin: Often used for food-grade or less demanding products.

       Outer Coating: Primer + topcoat (ink), providing color, patterns, and protection.

Manufacturing Process, Technical Principles, and Key Procurement Points for Aerosol Cans 2

2. Tinplate (Steel) Cans:

   Application: Lower usage proportion in the cosmetics field compared to aluminum cans, mainly used for specific scenarios (e.g., requiring extremely high mechanical strength, cost-sensitive products, or special shape requirements).

   Advantages:

       High Mechanical Strength: Pressure and impact resistance superior to aluminum cans.

       Potentially Lower Cost: Raw material cost may be lower than aluminum for certain specifications or large volumes.

       Mature Welding Process: The can body has a seam (side seam welding).

   Disadvantages:

       Heavyweight: Higher transportation costs.

       Prone to Rusting: Requires strict internal and external coating protection.

       Relatively Poor Malleability: Higher difficulty and cost for irregular shaping compared to aluminum cans.

       Aesthetics: The seam affects integrity and premium feel.

   Coatings: Also require high-performance inner coatings (epoxy-phenolic, PVDF, etc.) and outer coatings.

2.  Classification of Aerosol Cans

Manufacturing Process, Technical Principles, and Key Procurement Points for Aerosol Cans 3

1. By Dispersion Form of Contents:

   Spray: Liquid is dispensed as a fine mist (e.g., sunscreen spray, setting spray, perfume, hair spray). Relies on valve and actuator design.

   Foam: Dispenses dense, stable foam (e.g., shaving foam, cleansing mousse, mousse). Requires specific foam valves and formulations (containing foaming agents).

   Mousse: Similar to foam, but usually lighter and more airy (e.g., hair styling mousse, body mousse). Higher requirements for valves and formulations.

   Ointment/Cream: Dispenses semi-solid paste or cream (e.g., some ointments, special skincare products). Requires special valve design.

   Stream: Dispenses a continuous liquid stream (e.g., some cleaning agents, special-purpose products).

2. By Valve System Technology:

   Traditional Valve (Conventional Valve): Propellant and contents are mixed in the same chamber. Lower cost, widely used.

   Bag-On-Valve (BOV):

       Principle: A flexible multi-layer composite bag (usually aluminum-plastic laminate) is inside the can. The contents are filled into the bag, and the propellant (usually compressed gas like N2 or compressed air) is filled between the bag and the can wall. When the valve is pressed, only the contents are expelled; the propellant does not contact the contents.

       Advantages:

           Pure Contents: Propellant does not mix with contents, suitable for sensitive formulations (e.g., preservative-free, high active ingredients, viscous formulations, oxygen-containing formulations).

           Stable Dispensing: Stable dispensing regardless of can orientation or remaining content, until exhaustion.

           No Solvent Contamination: Pure compressed gases can be used, no VOC (Volatile Organic Compounds) issues.

           Wide Formulation Compatibility: Can fill very viscous or particle-containing formulations.

           Environmentally Friendly: No need for propellants like LPG (Liquefied Petroleum Gas) or DME (Dimethyl Ether).

       Disadvantage: Cost significantly higher than traditional valve systems.

   Piston Valve: A piston inside the can physically separates the contents from the propellant. Also enables pure dispensing and orientation independence, but the structure is more complex than BOV, the cost is also high, and its application in cosmetics is not as widespread as BOV.

3. By Can Body Shape:

   Straight Wall Can

   Waisted Can (more ergonomic)

   Irregular Shaped Can (achieved through mold impact extrusion and drawing, where aluminum cans have a clear advantage).

3.  Aerosol Can Manufacturing Process (Using Mainstream Aluminum Cans as an Example)

1. Can Body Manufacturing:

   Cupping: Aluminum coil is punched by a press to create circular cups.

   Drawing and Ironing (D&I): The cups are forcefully drawn and ironed through multi-stage dies, thinning the can wall and increasing the can height to achieve the target diameter and height. This is the key process for seamless aluminum can forming.

   Cleaning: Removes lubricants and impurities.

   Internal Spraying: The inside of the can body is sprayed with a specific coating and cured at high temperature.

   Necking/Flanging: The can opening is necked down to accommodate the valve, and a flange is formed for seaming.

   External Spraying/Printing: The outside of the can body is coated with primer, printed with designs, and coated with varnish, with curing required for each layer.

2. Top Cap/Bottom Cap Manufacturing (if applicable):

   Aluminum stamping.

   Cleaning, spraying (internal/external), printing (top cap exterior).

3. Valve Manufacturing:

   This is a precision component, usually produced by specialized valve factories. Includes valve body, stem, gasket, spring, actuator (nozzle), overcap, etc. Involves complex processes like injection molding, metal stamping, and assembly. The quality and design of the valve directly determine dispensing performance and safety.

4. Can Assembly:

   For three-piece cans (mainly tinplate): Weld can body side seam → Internal/external spraying → Necking/flanging → Install bottom cap (seaming) → Install top cap (seaming).

   For two-piece aluminum cans: Can body D&I forming (includes bottom) → Internal spraying → Necking/flanging → External spraying/printing → Install valve and top cap assembly (crimping). This is the most critical final step for aluminum cans.

   Crimping (Clinch / Crimp): The valve mounting cup is placed on the can opening flange and tightly rolled/seamed onto the opening by a crimping machine, forming an airtight seal. This process requires extremely high precision and consistency.

5. Leak Testing: Assembled empty cans must undergo strict leak testing (often helium leak testing or high-pressure water bath testing).

Manufacturing Process, Technical Principles, and Key Procurement Points for Aerosol Cans 4

6. Filling:

   Traditional Valve Can: Typically, contents are filled first, then liquefied propellant is charged (pressed in under high pressure through the valve or injected under low pressure and the valve sealed afterward).

   BOV Can: The empty bag is first placed into the can and fixed to the valve → Crimping → Fill contents into the bag through the valve → Charge compressed gas between the bag and can wall through a special channel under the valve → Finally seal the gas charging channel.

4.  Technical Principle of Aerosol Cans

Core Principle: Pressure difference drive. The internal pressure is maintained higher than atmospheric pressure.

Traditional Valve System:

1.  Liquefied propellant (e.g., LPG, DME) or compressed gas (N2, CO2) is mixed with the contents (or partially dissolved/suspended).

2.  Liquefied propellant exists in gas-liquid equilibrium within the can, providing constant vapor pressure. Compressed gas provides constant pressure.

3.  Pressing the actuator (nozzle) opens the valve.

4.  High pressure pushes the contents (which may be mixed with propellant) up through the valve stem.

5.  The contents are expelled through a small orifice or special structure (e.g., foam chamber) in the actuator.

6.  Upon expulsion, pressure drops sharply:

       Liquefied propellant rapidly vaporizes and expands, breaking the contents into fine mist droplets (spray).

       If the formulation contains foaming agents and the valve has a foam chamber, foam is formed.

Bag-On-Valve (BOV) System:

1.  Compressed gas (N2 or compressed air) fills the space between the flexible bag and the can wall.

2.  Pressing the actuator opens the valve.

3.  External gas pressure uniformly compresses the flexible bag.

4.  The contents inside the bag are squeezed out and expelled through the valve stem and actuator.

5.  The dispersion form is determined by the properties of the contents and the actuator design (mist, foam, paste, stream). The propellant gas is not expelled, only acting as the pressure source.

Manufacturing Process, Technical Principles, and Key Procurement Points for Aerosol Cans 5

5.  Aerosol Can Cost Structure

1. Raw Material Costs:

   Can Body: Aluminum or tinplate (greatly affected by international commodity price fluctuations).

   Coatings/Inks: High-performance inner coatings (especially PVDF), outer coatings, printing inks.

   Valve System: Complex composition (plastic pellets, metal parts, rubber seals, springs, etc.), a major cost component. BOV valve cost is much higher than traditional valves (involving composite film bags, special structures).

   Propellant: LPG/DME (traditional valve) or compressed gas N2/Air (BOV). Compressed gas cost for BOV is relatively low.

2. Manufacturing Costs:

   Can Processing: Equipment and energy costs for D&I process (aluminum cans) or welding, seaming processes (steel cans). Mold costs (especially for irregular shaped cans).

   Printing/Coating: Costs for multiple spraying, printing, and curing processes.

   Valve Manufacturing: Labor and equipment costs for precision injection molding, stamping, and assembly.

   Assembly/Crimping: High precision and maintenance costs for crimping equipment.

   Testing Costs: Strict online and offline testing (leak, dimensions, performance, coating integrity, compatibility testing, etc.).

3. Mold and Development Costs:

   High costs for designing new can types, new valve structures, and developing molds (can body, valve components), which need to be amortized.

4. Testing and Certification Costs:

   Content compatibility testing, long-term stability testing, valve functional life testing, safety testing (pressure, leakage, flammability), regulatory certifications (vary by country globally).

5. Minimum Order Quantity (MOQ) and Packaging Logistics:

   Aerosol can MOQs are usually high (tens of thousands to hundreds of thousands), tying up capital and inventory. Empty cans are pressure vessels, requiring special transportation requirements (e.g., protective caps, anti-stacking requirements).

6. Filling Costs:

   Brands need to invest in dedicated aerosol filling lines. Filling processes are complex, relatively slow, and have high safety requirements.

6.  Aerosol Can Quality Control Requirements

1. Raw Material Control:

   Thickness, mechanical properties, and chemical composition of aluminum coil/tinplate substrate.

   Specifications, food safety/regulatory compliance certificates for internal and external coating materials.

   Material certificates, compatibility test reports for all valve components (plastic, rubber, metal).

   Propellant purity, specifications.

2. Production Process Control:

   Can Body:

       Dimensional accuracy (height, diameter, necking dimensions).

       Coating integrity (Inner coat: conductivity test or copper sulfate test; Outer coat: adhesion, abrasion resistance, corrosion resistance).

       Print quality (color, registration accuracy, free from defects).

       Appearance defects (scratches, dents, contamination).

   Valve:

       Critical dimensional accuracy (affects crimp seal and function).

       Correct assembly of all components, no missing parts.

       Seal performance.

   Crimping:

       Core! Crimp dimensions (height, width, countersink depth) must be strictly controlled within tolerance to ensure airtightness and pressure resistance. 100% online inspection (visual or mechanical measurement).

       Crimp appearance (free from deformation, burrs).

3. Leak Testing:

   100% online high-pressure water bath or helium mass spectrometry leak testing must be performed on assembled empty cans to ensure no micro-leaks.

4. Performance Testing:

   Valve Function: Dispensing amount, spray pattern (mist pattern, foam quality), actuation ease, stem reset ability.

   Valve Life: Simulated actuation cycle test (usually requires several thousand cycles or more).

   Sealability: Pressure change, weight loss after long-term storage or heat storage.

   Pressure Resistance Test: Burst pressure test (far higher than working pressure and safety relief valve setting).

   Compatibility Testing: Top Priority! After filling with the final formulation, conduct long-term stability tests (under different temperature, light conditions), observing can corrosion, coating peeling, content discoloration/deterioration, odor, change in dispersion form, pressure stability, etc. Usually includes 3-6 months of accelerated aging tests.

5. Safety Device Check:

   Ensure the safety relief valve (if present) functions correctly.

6. Finished Product Inspection:

   Sampling inspection for appearance, net content, dispensing performance (according to AQL standards).

Manufacturing Process, Technical Principles, and Key Procurement Points for Aerosol Cans 6

7.  Key Procurement Points for Aerosol Cans

1. Define Requirements:

   Product form (spray/foam/mousse/paste) Content properties (pH, solvents, active ingredients, viscosity) Target market and regulations Expected fill volume Filling speed Cost budget Packaging design (can type, size, printing requirements) Need for special technology (e.g., BOV)

2. Supplier Selection:

   Expertise and Experience: Specializes in cosmetic aerosol cans, has successful cases (especially similar products), familiar with regulations.

   Technical Capability: Possesses can design, valve selection, compatibility assessment capabilities. Has BOV technology

   Quality System: Sound ISO/GMP system, strict online and offline testing equipment (especially crimp inspection, leak detection).

   Production Equipment and Capacity: Equipment advancement, stability, capacity to meet demand.

   R&D and Testing Capability: In-house laboratory capable of key compatibility and functional tests.

   Cost and MOQ: Price competitiveness, acceptable minimum order quantity.

   Compliance: Materials comply with global target market regulations (REACH, RoHS, FDA, China’s Cosmetics Safety Technical [Cosmetics Safety Technical Specification], etc.), able to provide compliance certificates.

   Geographic Location and Supply Chain: Logistics convenience, risk resistance (single source risk).

   Environmental Qualifications: Material recyclability, environmental certifications for production processes.

3. Technical Communication and Sampling:

   In-depth communication on technical details (can type, valve, coating selection).

   Request blank samples and filled test samples for thorough validation (function, compatibility).

   Rigorous Testing: Fill samples with the actual formulation for comprehensive long-term stability testing (cannot be omitted!).

4. Contracts and Agreements:

   Clearly define technical specifications, quality standards (inspection standard AQL), acceptance criteria.

   Clarify mold ownership (usually belongs to the brand owner).

   Strict intellectual property and confidentiality agreements.

   Handling of quality non-conformities, claim clauses.

   Supply guarantee, delivery time, price adjustment mechanisms.

Manufacturing Process, Technical Principles, and Key Procurement Points for Aerosol Cans 7

8.  Aerosol Can Application Scenarios

Aerosol cans are extremely widely used in the cosmetics field, primarily leveraging their convenience, dosing, and unique form advantages:

1. Hair Care:

   Dry Styling: Hair spray, hair wax (spray type), hair mousse.

   Dry Shampoo/Volumizing Spray: Quick cleansing, adds volume.

   Hair Care Spray: Sun protection, heat protection, nutrient spray.

   Hair Color Spray: Temporary highlights, color touch-up.

2. Body Care:

   Sunscreen Spray: Even and quick coverage of large skin areas, fresh and non-sticky. BOV technology is growing fast in this application (pure formulations).

   Antiperspirant/Deodorant: Mainstream packaging form.

   Body Moisturizing/Cooling Spray: Instant hydration and cooling.

   After-Sun Repair Spray.

   Hair Removal Mousse/Foam.

   Body Mousse/Bubble Bath.

3. Facial Care:

   Setting Spray/Hydrating Mist: Fine mist.

   Cleansing Mousse: Direct foam output, convenient and gentle.

   Shaving Foam.

   Some Serum Sprays (require BOV to preserve activity).

   Color Cosmetics: Airbrush foundation/body highlighter (professional or home use), some setting products.

4. Perfume and Cologne: Traditional and important application.

5. Special Purpose:

   Hand/Foot Care Spray, Intimate Care Foam, Wig Care Spray, Instant Cold Pain Relief Spray (medicated).

Summary:

Aerosol cans are a type of cosmetic packaging with high technical content, strict regulatory requirements, and critical quality control. Aluminum cans have become the mainstream choice due to their comprehensive advantages. The choice of valve technology (traditional vs. BOV) is core to determining product performance, safety, and cost. Successful application relies on a deep understanding of materials, processes, and principles, deep technical cooperation with suppliers, and strict quality control throughout (especially crimp seal integrity, coating integrity, and content compatibility). Procurement requires comprehensive consideration of the supplier’s expertise, technical strength, quality system, and cost, along with sufficient sample testing and stability verification. With growing consumer demand for pure formulations, environmental protection, and convenient experiences, especially with the maturation of BOV technology, the application prospects for aerosol cans in the cosmetics field remain broad.