Aerosol Can Selection Guide: Materials, Sizes, Valves

Aerosol Can Selection Guide: Materials, Sizes, and Valve Types

The can is more than a container — it is a pressure vessel that must safely hold your product and propellant at 4-12 bar for years of shelf life. Choosing the right can involves four decisions: material, size, internal lining, and valve type. This guide covers all four.

Can Materials

Material	Pros	Cons	Best For
Tinplate (Steel)	Lowest cost, excellent pressure resistance, widely available	Can rust if internal lining fails; heavier than aluminum	80%+ of all aerosol products — air fresheners, insecticides, paints, car care
Aluminum	Lightweight, corrosion-resistant, premium appearance, no side seam	Higher cost (2-3× tinplate), lower burst pressure	Cosmetics, personal care, pharmaceuticals, premium consumer products
PET (Plastic)	Transparent, won’t corrode, lightweight	Limited pressure rating, higher cost, fewer suppliers	Niche cosmetics, transparent packaging concepts, low-pressure BOV

Internal Linings

Tinplate cans require an internal coating to prevent the product from contacting bare steel. The lining choice depends on your formulation:

• Epoxy: General purpose, good chemical resistance. Standard for most products.
• Phenolic: Superior acid resistance. For acidic formulations (certain insecticides, cleaners).
• PVC Organosol: Flexible coating. For products that cause epoxy to crack or delaminate.
• Double-coated (Epoxy + Phenolic): Maximum protection. For aggressive solvent-based products.

Testing tip: Always conduct a 48-hour oven test at 50°C with your actual formulation to verify lining compatibility. A lining that works with one air freshener formula may fail with another due to different fragrance solvents.

Can Sizes

Diameter	Common Heights	Typical Fill Volume	Common Products
35 mm	80-150 mm	50-150 ml	Travel-size, samples, small cosmetics
45 mm	100-200 mm	100-250 ml	Deodorants, personal care, medium air fresheners
52 mm	140-240 mm	200-400 ml	Standard air freshener, insecticide
57 mm	180-280 mm	300-500 ml	Large insecticides, industrial sprays
65 mm	200-330 mm	400-750 ml	Spray paint, tire foam, large-format products

Critical measurement: Can diameter determines which filling equipment you need. Our fillers handle 35-66 mm diameters as standard. Always confirm your can specifications before ordering equipment.

Can Size and Equipment Compatibility

Most semi-automatic filling stations handle a wide range of can sizes with quick tool-free adjustments. Automatic lines require change parts (guides, star wheels) for each can diameter — budget $1,000-3,000 per size for change parts if you plan to run multiple can sizes on one line.

Valve Types

Valve Type	Size	Sealing Method	Best For
Standard 1-Inch	25.4 mm	Capping (sealing jaw presses valve cup onto can)	80%+ of products — air fresheners, insecticides, paints, automotive
Ø20 mm Crimp	20 mm	Crimping (can neck mechanically deformed around valve)	Cosmetics, personal care, pharmaceuticals
BOV (Bag-on-Valve)	1-inch or custom	Under-cap gassing + through-stem fill + crimp	Premium cosmetics, pharmaceuticals, food, oxygen-sensitive products
Metered Dose	20 mm or 1-inch	Standard capping/crimping	Pharmaceuticals (50-100 µl per spray), precision-dosed products

Valve Components

A valve assembly includes:

• Stem: The tube the product flows through when the actuator is pressed
• Gasket: Seals the stem when not pressed. Material must be compatible with your formulation:
  • Buna-N (Nitrile): Standard for most products. Good with LPG, oils.
  • Neoprene: Better water resistance. For water-based formulas.
  • Butyl: Low permeability. For products where propellant loss is a concern.
  • EPDM: Excellent for ketones, alcohols. Avoid with petroleum solvents.
• Spring: Returns the stem to closed position. Stainless steel for most applications.
• Housing: Contains the stem, gasket, and spring. Connects to dip tube.
• Dip Tube: Draws product from the bottom of the can. Standard for upright spray.

Actuator (Spray Head) Selection

The actuator determines the spray pattern and is often overlooked during equipment planning. Key parameters:

• Orifice size: Smaller = finer mist but lower flow rate. Larger = wetter spray, higher flow.
• Insert type: Mechanical break-up (MBU) creates a cone pattern. Standard for most products.
• Non-mechanical break-up: Stream pattern. For products that foam or gel on contact.
• 360° actuator: Works upside down. For BOV products and specialty applications.

Packaging Checklist for New Manufacturers

1. ✅ Choose can material (tinplate for cost, aluminum for premium)
2. ✅ Select diameter and height based on fill volume + propellant ratio
3. ✅ Specify internal lining — and test with your actual formulation
4. ✅ Choose valve type (1-inch standard for most products)
5. ✅ Select gasket material compatible with your formula
6. ✅ Choose actuator type and orifice size
7. ✅ Source at least 2 suppliers for supply chain resilience
8. ✅ Order samples and test with your filling equipment before bulk purchase