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Many chlorinated solvents should never be formu- Production of Aluminum Aerosols
lated in aluminum cans. Propellent-11 (CCIsF) can
decompose to produce hydrogen gas in certain anhy-
drous compositions. If ethanol is present also, it
becomes particularly active, forming hydrogen, acetyl
chloride, aluminum chloride, hexachloroethane, Pro-
pellent-21 (CHC^F) and other products as the result of
a free radical reaction. The addition of water and a bit
of acid may eliminate this reaction, but in any case,
extreme caution is advised. The Dow Chemical Co. has
advised particularly against the incorporation of their
Aerothene TT solvent (inhibited 1,1,1-trichloroethane)
in formulas designed to be marketed in aluminum con-
tainers, or even in those that contain aluminum
powder, such as certain aerosol paint products.
A large number of substances act as corrosion pro-
moters for aluminum containers. As a rule, they are
least effective for highly purified (99.8 + %) aluminum,
more so for various aluminum alloys used in canmak-
ing. Chloride ion is a strong promoter, especially in
acidic media. Even trace quantities exert a major effect,
and this applies to bromide and iodide ions as well. Oxi-
dizing agents should be avoided, such as copper ion,
peroxides and traces of hypochlorite ion. Rather sur-
prisingly, certain reducing agents, such as sulfurous
acid, formic acid, esters and aldehydes can bring
about corrosion, but this may involve reactions by
which the aluminum reduces the reducing agent; e.g.
transforms an aldehyde to the alcohol. Fluoride ion is
said to be an inhibitor, and many of the usual inhibitors
used for tinplate cans have been found to be useful in
aluminum containers as well.
Because of the complexities surrounding the com-
patibility of aluminum and various aerosol formulas,
each formulation should be tested specifically for many
months in the suggested lined or unlined aluminum can
before being produced in commercial quantities.
Aluminum and tinplate can be used together with
greater freedom from corrosion than might be antici-
pated, when considered from the dissimilar metal elec-
trochemical standpoint. Tinplate bottoms are used
often to lessen costs and facilitate can handling by
avoiding the necessity of pucks on the production line.
Tinplate valve cups also are used commonly with
aluminum containers. In some cases, tinplate cans are
fitted with aluminum valve cups to increase their
resistance to attack by aggressive formulas, such as
distinctly acidic products.
Most captive and contract fillers can handle
aluminum cans that use a 1" (25.4 mm) closure. The 13
mm and 20 mm types are filled normally on' 'Tube and
Bottle Lines", since a special clinching machine is
required to pinch in the ferrule of the valve so that the
junction with the container becomes air-tight. To pro-
duce the clinch, a rather large and costly collet, about
6" (15.2 mm) long and carrying 16 to 24 tines, is
brought down over the valve ferrule and the tines are
then strongly pinched inward, using a sliding mandrel
sleeve. The ferrule wall is thus deformed, somewhat
like the cap of a soft drink bottle, in order to create the
hermetic seal with the can.
For most production lines larger than laboratory
scale models, aluminum (and glass) containers must be
inserted into puck carriers — simply called "pucks".
Otherwise the cans would tip over, fail to clear junction
areas, float in all but specially designed hot tanks, and
create other serious problems. A typical 200 foot (61 m)
production line, operating at 100 cpm, will require
about 650 pucks, and another 10% should be on hand
to allow for contingencies.
Pucks are available normally with either a magnetic-
ally susceptible stainless steel baseplate, or one or two
small bar magnets attached to the bottom area of a
polyethylene or polypropylene retaining cup. A
phosphor-bronze spring clip is used often to hold the
inserted container firmly in place. Each can diameter
(and bottle shape) normally will require a different set
of pucks. Upon request, the puck supplier can provide
pucks with differently colored plastic shells to designate
the container that it is designed to accommodate. Two
representative puck suppliers are State Manufacturing
Co., Chicago, and Terco, Inc., Schaumburg, IL (See
Company Listings).
Aside from puck handling, a production line for 1 "
(25.4 mm) aluminum cans will have to have a special
bottom coding device, sometimes special U-t-C gasser
centering bells (as in the case of 2.089" (53.0 mm)
diameter "Peerasol" cans), and perhaps special
machines to apply such fitments as polished metal
" wedding bands" when required. Extra large
aluminum cans may pose problems for the standard
aerosol line, simply due to their dimensions. Also, if
they are over 26.8 fl. oz. (793 ml) capacity, a special
DOT permit will be required for interstate shipments
within the U.S.A.
Commercial Aspects of Aluminum Cans
Aluminum cans are generally more costly than cor-
responding tinplate cans, even though they are only
about 50 to 60% as heavy. This is due to the much
higher cost of aluminum, which reflects the great
amount of energy needed to produce the metal. A
recent statement by Alusuisse suggests that 28% of all
aluminum is now recycled, at an energy cost of 5% that
needed to produce the virgin metal, so this may help the
cost situation somewhat in the long range. In India,
aluminum cans are extruded or drawn using metal pro-
duced in that country from their extensive bauxite
deposits. To protect the industry, an importation tariff
of about 250% is levied against tinplate cans. As a
result of this artificial economic situation India's small
aerosol industry now uses a great preponderance of
aluminum containers.
With rare exceptions, such as the Tube Manifold
cans, the tinplate and steel containers lie within a
capacity range of 3.4 to 26.8 fl. oz. (100.5 to 793 ml).
Aluminum cans are not subject to these limitations, and
can extend from 0.3 to at least 45 fl. oz. (8.9 to 1,520
ml). The smaller sizes compete with glass, coated glass
and plastic for such products as perfumes, breath
fresheners and medicinals, while the larger sizes are
used for industrial and institutional products, such as
dairy barn insecticides.
The seamless aluminum containers often can be
decorated with strikng impact. The use of silver and
gold blocked decors, burnished finishes, brushed tex-
tured effects, iridescent metallic dye painting, wedding
band and matching cap closures all contribute to sug-
gest that aluminum cans may, at a price, be embel-
lished with today's most sophisticated and beautiful
decorative techniques. Such firms as the Risdon
Manufacturing Co., and AndBro, Inc. specialize in
high quality custom decoration. Their capabilities often
may extend significantly beyond those of the aluminum
can manufacturer. Despite the extra expense and
delay, they should be considered when a particularly
elegant container is needed.
Aluminum is often able to hold products quite cor-
rosive to tinplate. This may relate to the unique proper-
ties of the metal, or the ability to line the can completely
with up to four or more coatings of enamel without any
seams or bridging problems to contend with, as would
be the case with tinplate. Also, since it is incapable of
rusting in the standard sense, aluminum cans will not
leave rings of corrosion product as stains in a wet or
humid environment.
Aluminum cans can be developed into packages of a
simple cylindrical design, but tinplate welded and
double necked-in cans can come very close to this ideal.
Aluminum cans may be produced with a certain degree
of contouring. So may tinplate cans, but normally at a
much higher cost, unless the sales volume is enormous.
Both aluminum and tinplate cans can be used for inner-
container barrier-pack systems. At this time, only the
seamless aluminum can is fully adaptable to piston
packaging, although welded tinplate cans may be
developed with this capability within a year or two.
These special container types are described later in this
chapter.
Stainless Steel and Other Aerosol Containers
A very small market exists for stainless steel aerosol
cans, particularly in the half to one fl. oz. (15 to 30 ml)
range. They have the "S-type" 20 mm finish, because
the alloy would tend to crack if worked into a bead
finish design. These units obviously are expensive and
can be justified for use only with costly products that are
sensitive to aluminum metal, for example, a few
delicate pharmaceutical items. These cans are available
from the Virjune Manufacturing Co., Emson
Research, Inc. and perhaps other firms.
Large stainless steel aerosol cans of the returnable
type are still available. They cost in the area of $7.00
each, in the 14 to 19 fl. oz. (414 to 562 ml) range. They
are one piece units made by electrowelding top and bot-
tom sections, followed by grinding and polishing. A
typical application is for whipped cream dispensing,
since they can be charged with up to 400 psig (2.76 Pa)
and will then deliver a superior, fluffy product when
dispensed.
Most of Eric Rotheim's early aerosol cans (1922)
were made of heavy-walled brass shells, brazed
together at the center. Some twenty years later, some
experimental cans were made of brass and bronze by
Westinghouse. But the properties and relatively high
cost of these copper alloys was never conducive to com-
mercialization, and with one possible exception occur-
ing in Eastern Europe, such aerosol cans have never
been made in quantity.
At present (1982) aerosol cans, except those of pure
99.8% aluminum, contain up to four metals. For
example, a high lead, high strength, soldered tinplate
can will contain iron, tin, lead and either silver or
antimony. Other metals are present in the steel alloy;
e.g. Type MR steel contains a maximum of 0.20%
copper. As a logical extension of tin and CCO plated
steels the can companies have experimented with clad
plate: LCDD and other steel alloys coated with nickel,
monel metal or even aluminum. These metals are fused
to the steel using special techniques, after which the
plate is rolled to the final thickness. One of these metal
companies, after rolling to a 100 Ib. baseweight, might
consist of 0.001 " (25.4 m) of monel, 0.008 " (203 m) of
steel and 0.002 " (50.8 m) of monel. The heavier monel
coating would be designed to go against aggressive
products. In practice, however, the high cost of clad
plate effectively prevented its use for aerosol cans. Some
clad valve cups were used about 1972, but in very
limited quantities. They cost about as much as stainless
steel valve cups and very few products could afford such
exotic packaging luxuries.
Figure 44. Some Tall Commercial Aerosol Cans
Illustrated are some of the tallest commercial cans of their respec-
tive diameters. The unit at left is a 207.5x1113 "bazooka-type"
made in France for hair sprays and other products. The large dark
can is made by Hi-Pac Co., for industrial applications and is return-
able. It has been used for mineral oil based egg coating sprays. The
other two are a 211 X908 FIK insecticide by The d-Con Company,
and a 300 x 709 spray foam rug shampoo by Carbona Corporaiton.
The Paper Labeling of Aerosol Containers
Aerosol cans may be decorated directly upon the
basecoated metal, using a number of techniques men-
tioned earlier, or by using paper labels. Paper or foil
labeling is used for about one tinplate container in five;
more rarely in the case of aluminum cans, except in the
larger sizes. It provides these unique advantages:
a. Warm, elegant feel.
b. Ideally suitable for short runs, especially under
25,000 units.
c. Can be decorated in every imaginable combina-
tion of colors, metallics, half-tones and shades.
Foil laminates provide an extra measure of gloss
and other effects.
d. Labels may be embossed or debossed for special
effects.
e. They cover the welded side seam slag line and
soldered area of three piece cans.
f. They can be overprinted to provide distributor
information, even in the case of very small pro-
ductions. Similarly, such things as phar-
maceutical expire dates, slot codes, coupon deals
and so forth can be applied to existing label stocks.
g. They can be used to mask obsolete or defective
lithography, so that the value of the aerosol can
(up to $0.49 each for tinplate 300 x 709s in 1981)
can be salvaged.
h. They help minimize inventory costs — important
for firms with cash flow and warehouse limita-
tions.
When ordering paper labels it is vital to specify cor-
rect dimensions of paper and printing, as well as other
criteria. In the case of tinplate cans made in the U.S.A.,
suggested dimensions are shown in Table XXVI. For
aluminum cans, these same concepts may be used,
referring also to the manufacturer's recommendations
for label height, as indicated in Table XXV and Figure
42. Reduced heights can be used for aluminum cans if
desired, but for three-piece regular cans, labels should
fit rather snugly between the double seams.
Paper labels should be made of reasonably good
stock running about 60 ± 10# in thickness. Individual
preferences may differ, but it is generally considered
that the grain should run the long (horizontal) way of
the label for minimum labeler losses. When the grain
runs the long way, wetting the back of the label with
water will cause it to curl into the longest possible tube.
 The glue lap position should be specified to the sup- d. Embossed and foil-coated labels are very expen-
plier. Most often it is located at the left hand margin. sive when purchased in relatively low volumes.
Slight champfers are used occasionally at the corners e. During use, paper labels may absorb grease,
opposite the lap area. They act to reduce the unsight- grime and dirt, making the label unsightly.
liness of sharp edges visible on slightly spiraled labels.
Most labels are packaged in bundles of 1000 (some- In addition to regular paper labeling, paper labels
times 500), and preferably with heavy cardboard at top may also be attached to cans (and bottles) as window
and bottom, using moisture resistant paper. They panels, metallized medallions, bottom discs (often
should be shipped packed tightly in sturdy corrugate, or giving the name and address of the manufacturer, net
even wooden cases, to minimize "dog ears" and other weight, code or other vital data) and (rarely) as a cover
problems. Any labels remaining in opened packages for special plugs or valves fitted into the base section of
should be resealed to prevent curling due to humidity. compartmented or piston aerosol cans. In some cases,
they may be wrapped around the top inch (25.4 mm) or
Depending upon dimensions, composition (foil-
two of the can, or around the side wall of the cover cap
faced, etc.), packaging, size of the production run,
to provide the purchaser with a coupon, a contest ticket,
condition of the paper labeler, expertise of the operator,
or some special information. Spot labels are sometimes
glue selection and other factors, label losses will run
affixed to the top of covercaps using contact adhesives,
between 2 to 5%. In rare cases they may get to 15% or
in order to give the retail store a place to print the price
even cause shut-down of the production line.
or to embellish the otherwise plain upper portion of the
Paper labels have a series of disadvantages, sum- dispenser.
marized as follows:
Lithographic Decoration
a. Labeling operations may reduce line speeds by 3
to 10%, thus increasing filling costs. Lithography is used on about 80% of tinplate cans
b. They have rather limited water resistance, made today, and may be expected to become even more
although foil-faced labels are better, and should popular if the fledgling trend toward necked-in cans
not be used where they can become wet and continues. Many aluminum cans are also lithographed,
especially the smaller sizes. The procedure for develop-
wrinkled.
ing a final lithographed can is outlined as follows:
c. Considering the overall AQL (Acceptable Quality
Level) of the finished aerosol unit, the use of paper a. The crude label is developed and checked for
labels often has a mildly depressing effect on compliance with existing government regulations.
quality. b. The sketch is provided to commercial artists for
TABLEXXVI
Specifications for Paper Labels Used for Steel and Tinplate Cans
24 oz. 20 oz. 18 oz. 16 oz. 16 oz. 14 oz. 14 oz. 12 oz. 12 oz. 12 oz. 12 oz.
Dimensions 30Ox 211 x 211 x 211 x 207.5 x 211 x 207.5 x 211 x 207.5 x 214 x 202 x
709 713 612 604 701 510 605 413 509 411* 708
Capacity (ml) 793 649 564 523 493 472 443 403 386 368 398

Length 9 1 Vi 6 " 8V 4 " 8V4" 83/4" 8V 8 " 8 3 A" 8Vs" 8V 4 " 8V 8 " 95A6" 7V 32 "

Height, av. 7 7 / 32 " 7 1 Vi 6 " 6 1 V 32 " 5 2 V 32 " 6 2 V 32 " 59/32" 5 3 V 32 " 5 1 V 32 " 5% 2 " 5 1 V 32 " 7V 32 "
7 1
Height, max. 7V 4 " 7V 2 " 6 A6" 5 Vi 6 " 6V 4 " 5Vi 6 " 6" 5V 2 " 5V 4 " 5V 8 " 7Vi 6 "

Total length 9Vi 6 " 81A" 8V 4 " 8V 4 " 7V 8 " 8V 4 " 7V 8 " 81A" 7V 8 " 8 13 A 6 " 6 2 V 32 "
of printing*

Length of 91A6" 8V 8 " 8V 8 " 8V 8 " 7V 2 " 8Vs" 7V 2 " 8V 8 " 7V 2 " 8 11 A 6 " 617/32"
live matter

Length of 91A6" 8V 8 " 8V 8 " 8V 8 " 7V 2 " 8V 8 " 7V 2 " 8V 8 " 7V 2 " 8 1 V 16 " 6 1 V 32 "
Gloss Coat

* Includes V 8 " bleed area under % " lap. * "Two-piece drawn can.
 final designing, which leads to a product called
"artwork" in the trade.
c. After approval by the marketer, the artwork is
processed by the canmaker into "black and white
proofs" (actually blue and white, today).
d. The proofs and color swatch samples are then
approved by the marketer and the can supplier
then prepares "press plates", using contact
negative photoengraving techniques.
e. Unless they happen to be made at the same loca-
tion, the press plates are then forwarded to the
lithographing can plants, where the cans will be
manufactured.
Marketers often ask the can companies to supply
"Color Tolerance Booklets" for their cans. Each
booklet contains a set of three can bodies in the flat,
showing the lightest, the average and the darkest color
Figure 45. Plain and Lithographed Aerosol Cans
combination the canmaker proposes to supply. These A plain, white enameled Crown Cork & Seal Company 6 oz. "Spra-
booklets are sometimes used by the quality assurance tainer" ready for either silk-screening (rare) or paper labeling, com-
department of the marketer or contract filler in order to pared with a comparable lithographed can of GONE, a hair remover
foam, with an obsolete 5.3 fl. oz. fill declaration.
maintain reasonable color uniformity of the finished
lithographed plate.
During the latter 1960s tinplate bodies were some-
In addition to standard lithography, done in the flat, times embossed about 0.004 " (100 /mi) so that the metal
dry offset lithography and other processes may be used could be used to highlight and accentuate printing
to decorate containers that have already been formed; designs. This practice has now been discontinued.
e.g. aluminum cans. Silk screening is an option, where Various textured designs have appeared, where extra
short runs are planned and only one or two colors are thick areas of the print coat are used to create a
acceptable. marginal three-dimensional effect. In some cases the

TABLE XXVIB

Nominal size I2 oz. 10 oz. 11 oz. 9 oz. 7 oz. 6 oz. 6 oz. 5 oz. 4 oz. 3 oz.
Dimemi
°nS 211x 207
'5* 202 x 202 x 202 x 202 x 202 x 113 x 202 x 202 x
411 413
* 700 509 406 411* 314 411 214 200
Capacity (ml) 387 336 372 287 223 216 197 176 144 98

Le
ngth 83/8" 8V 8 " 7V 32 " 7% 2 " 7% 2 " 7Y 32 " 7% 2 " 6%" 7Y 32 " 7V 32 "

Height, max. 4*/16" 4 3 V 64 " 6 1 V 16 " 5V 4 " 4Vi 6 " 39/16" 3l%2" 4V 16 " 29/16" PV 16 "

Height, aver. 4 1 V 32 " 4 3 V 64 " 6 2 V 32 " 5V 32 " 4V 32 " 3 1 V 32 " 3V 2 " 413/32" 2 1 V 32 " I2V32"

8% 75/8 62V32 62V32 62V32 62V32 62V32 5% 62V32 621/32

Jprint^- " " " " " " " " " "

Le11S*of 8V 8 " 7V 2 " 6 1 V 32 " 6 1 V 32 " 6 1 V 32 " 6 1 V 32 " 6 1 V 32 " 55/8" 6 1 V 32 " 6 1 V 32 "
live matter

Length of
gloss coat 8V8" 7V 2 " 6 1 V 32 " 6 1 V 32 " 6 1 V 32 " 6 1 V 32 " 6 1 V 32 " 5V8" 6 1 V 32 " 6 1 V 32 "

*Two-piece drawn cans. "Includes V 8 " bleed area under V8 " lap.
appearance of texturizing can be achieved by the use of
color combinations, as in some matte and leatherette
finishes.
The durability of modern lithographic decorations
allows the can maker to utilize several types of metal-
working techniques on the body, such as double seam
bending, necking-in, and can forming operations. The
decoration survives these procedures remarkably well.
On the dome, such decorative finishes as, clear lacquer,
base coat and varnish, and base coat, print and varnish
may be applied before the progressive die-forming
operations that turn the flat disc into the finished con-
tour. Dome printing should be applied in terms of short
and simple words, such as "Shake Before Use" (never
"Shake The Can Before Using"), so that the user can
read the precaution without turning the can around
totally. Also, the words may drift somewhat, since the
metal stretches unevenly when going through the die
press. The words should never be underlined, since this
merely highlights the waviness problem.
Container Shaping
The now defunct Hunter-Douglas Co. in California
was perhaps the first aerosol manufacturer to produce
shaped cans. About 1957 they produced 202-diameter
aluminum units in a variety of contours. Some failed,
such as accordion-shaped cans, which "grew" during
hot tanking as a result of the high internal pressures that
were developed. Most were well designed and were
offered to an industry that was simply not ready to
accept them.
During the mid-1960s the Boxal Sales Division of
Alsuisse provided conies, Gibson Girl (narrow-waisted)
and other cans, but they were rarely seen in the Euro-
pean markets. More recently, the firm has introduced
well over twenty contoured aluminum cans, some
customized and others available from stock, all with the
upper portion especially shaped to provide a high
degree of individuality, as shown in Figure 26 and the
Brut 33 cans, Figure 30.
The first contoured tinplate aerosol cans were pro-
duced by the Continental Can Co., using their elec-
troforged Cono-weld side seam units. By the year 1969
the technology had been developed at Continental Can
Co. 's R&E Center in Chicago for what was termed the
"Electro-hydraulic Can Forming Process", in which
the lithographed can body was placed in a shaping mold
and filled with a sturdy rubber cylinder, containing a
pair of electrodes and some electrolyte solution. Suffi-
cient current is passed through the electrodes to pro-
duce a known amount of hydrogen gas, sufficient to
expand the sealed rubber diaphragm very hard against
the can body, forcing the metal outward to assume the
contour of the shaping mold. The gas is then released
and the mold opened to remove the expanded can
body. This method is suitable only for expanding the
body several per cent beyond the nominal double seam
diameter. It was never used to any extent in the aerosol
industry as things turned out, mainly due to extra costs
involved. Several molds had to be prepared, and the
cans were made more costly due to this added produc-
tion step. However, the process was used to make a
popular beer-barrel shaped 12 fl. oz. beer can during
the early 1970s.
Continental Can Co. has since used several other can
shaping methods, in one notable instance providing
inwardly shaped cans for a large antiperspirant
marketer. The economics of aerosol marketing pro-
grams later caused a reversion back to the standard
cylindrical container.
Shaping may be applied to the low-temper bodies of
tinplate and CCO welded cans, but not to drawn or
drawn-and-ironed tinplate cans, unless the high temper
is first relieved by annealing. This added treatment
would be too costly to consider seriously. Many designs
give rise to contoured cans that have a special panel for
the product trade name. Whenever the contouring is of
this type (not homogeneous around the can body), the
lithographed can will have to be registered accurately in
the mold before shaping. Also, during shaping, the can
wall is often pulled toward the shaped area, generally
more in one place than another. This means that
shaped can bodies must then be trimmed to length,
necked-in (as a rule) and flanged, before assembling the
end units.
Other options have been used occasionally to try to
convey contouring to aerosol cans, even to the extent of
fitting the aerosol entirely within a plastic outer con-
tainer, as in some products marketed during the 1970s
in Italy. Various shapes can be suggested for plastic
overcaps, particularly those which fit over the top
double seam of necked-in cans. A line of antiperspirants
sold in England was distinguished by a cover having a
ball-like shape, giving the product a rather perspicuous
phallic silhouette. In rare instances, the impression of
contouring has been achieved by using plastic snap-on
fitments that go over the bottom double seam. How-
ever, they are a direct extra cost item, tend to com-
Figure 46. Exploded Aerosol Can Due to Fire/Heat
The cleaned body and base sections of an aerosol dispenser that
had been placed in a fire and heated until the pressure of the con-
tents everted and then blew off the dome.
Figure 47. Cut Away of Three-Piece Soldered Can
A three-piece soldered side seam can opened for inspection of the
interior surfaces to check for possible corrosion. Shown with a can
of NU-TOX insecticide (made in 1960s) bulged to an unusual degree
before the body split, when thrown accidentally into a fire.

plicate packaging, and add to shelf space requirements In ordinary three-piece tinplate aerosol cans, when
if they flare outward. In one unique instance, a overheating occurs dome eversion will result, then base
decorator base of metallized plastic was used to snap inversion and finally rupture, as the top or bottom seam
onto a necked-in bottom double seam and extend unwraps and one of the ends blows off. In some cases,
upward to cover the bottom 25% or so of the can with a the base will evert first, or the dome will evert and
delicate filigree design. separate before the base inverts. Quite rarely, the body
As the aerosol industry moves into the 1980s, many metal will bulge and then tear apart before the ends
of these costly decorations are being set aside in favor of separate. If a soldered side seam is involved, it will fre-
the simple, straight cylindrical approach. Aerosols quently soften in a fire, causing rupture to occur at that
already suffer somewhat from an over-packaging location before anything else happens. Many exploded
image, and products that deliberately add obvious lux- aerosol cans will be found to have bodies with signifi-
ury tend to be passed over by an increasingly economy ca/it bulging. The two photographs illustrate aerosol
minded public. cans where significant body bulging took place, prior to
rupture.
Aerosol Can Safety Devices
Even though empty cans and bottles are non- TABLEXXVU
combustible, all too often aerosol dispensers have been
Pressure of Various Aerosols At Elevated Temperatures
disposed of by incineration. Despite precautionary
instructions there are reports of aerosols tossed into the Aerosol Pressure (psig)
backyard burn-barrel, an apartment house incinerator, Spray Starch Spray Starch Air Freshener
TempeTature (5% A-31) (5% A-31) (31% A-46)
or large city refuse treatment centers. They may be 0
C Air-Free (20"Hg°Vac. Cr.)* Air-Free*
overheated by exposure to furnaces, stoves, sunlight or
100 38 59 65 80
other forms of thermal energy. One large car maker 120 49 84 91 110
measured 2650F (13O0C) in the glove compartment of a 140 60 111 119 147
black automobile, in a set of "worst case" conditions. 160 71 153 162 191
180 82 181 191 243
Another measured a still higher temperature in the 200 93 223 235 305
heated air emitted by under-seat car heater pipes. Any
or all of these conditions are sufficient to cause ordinary * As percent head space decreases the incremental pressure of air rises, due to
greater reduction of the head space when adding the propellent.
aerosol cans to evert and then burst. Table XXVII pro-
vides an indication of the pressure rise in aerosol units **Example considers a minimum head space, thus minimizing preferential
evaporation of propane as the dispenser is heated, yet without liquid filling the
when exposed to high temperatures. dispenser, even at 20O0F (930C).
 In the case of two-piece tinplate or aluminum
aerosol cans, the end section normally bulges out and
then separates. For Monobloc aluminum cans, the
valve generally loosens to allow gross product leakage.
In some cases, it blows off when the pressure exceeds
about 400 psig (2.76 MPa). In a few cases, aerosol cans
will vent through the valve hole in the cup, after the
plastic portions of the valve have melted or burned
away in a fire.
Cans that are emptied of all but a few grams of the
product cannot develop excessive pressures when
strongly heated. After the last of the propellent has
turned into the gaseous phase any further increase in
pressure will be slow, more or less in accordance with
Charles' Law. Such cans may still explode, first as a
result of solder softening and creep, or in the case of
welded or seamless cans, when the can metal becomes
hot enough to be significantly softened. For example,
most steels lose about half their strength when heated to
95O0F, and soften rapidly after that.
There is no real agreement within the industry as to
how serious the problem of can bursting is, from a con-
sumer safety and property damage standpoint. No
reliable records have been kept. At a recent gathering of
industry experts, it was estimated that there may be as
many as 2 to 6 aerosol explosions per year in the U.S.A.
that have serious health and safety consequences to
people. This averages out to about one disfiguring, life
threatening or possibly lethal accident for every 500 to
600 million units sold... a safety record better than that
of over a hundred other commodities commonly found
in the marketplace.
Other sources suggest a higher rate of injuries.
About 1970 a survey of 600 U.S.A. insurance com-
panies was conducted by the U.S. Department of
Health, Education and Welfare. On an annualized
basis, they reviewed 10,328 closed product liability
claims and found eight which specified aerosol explo-
sions; e.g. 0.77%. A similar survey covered 2,500
physicians, who handled 12,750 product related injur-
ies in a two-week period. Three involved aerosol burns
to the upper body, but it is not known if the burns were
caused by bursting aerosol cans or by ignition of the
sprayed contents. The National Electronic Injury
Surveillance System (NEISS) was started in July, 1969
under HEW and later transferred to the Consumer
Product Safety Commission (CPSC) in the early 1970s.
Although the industry has been strongly opposed to the
interpretation of results, nevertheless, in one survey
period lasting 19 months and covering 244,938 injuries,

TABLEXXVIU
Critical Pressure Ranges for Tinplate and Aluminum Aerosol Containers
Bursting
Typical Pressure Range (psig) Temperature
Dot Container of Typical
Specification Dome Eversion Base Inversion Bursting Starch Can**

DOT Specification 2N** 150- 170 160 - 180 220 - 245 20O0F
(tinplate and CCO)

DOT Specification 2P 170- 190 180 - 200 245 - 275 2110F

(tinplate and CCO)

DOT Specification 2Q 190-210 200 - 225 275-310 22O0F

(tinplate and CCO)

(NCC Experimental 320 - 350 No data 430 - 465 2650F

Can- 165#ends.)

Small Aluminum Cans n/a. None 375 - 500 —

(Standard wall)

Small Aluminum Cans n/a. Minimal 800 - 1250 —

(0.030"min. wall)

*U.S. Department of Transportation Tariff No. 6000-A (1981).

**The example given in Table XXVII, with 5% A-31 and a 20" Hg0 (-69 kPa) vacuum crimp.
***Sometimes called a non-specification can.
Note: Standard European aluminum cans have 12 bar (174 psig) test pressure and 14.4 bar (208 psig) burst pressure minimums. High strength ones have 16 bar (232 psig)
test pressure and 19.2 bar (278 psig) burst pressure minimums.
only five cases were related to aerosol explosions.
Most can explosions result from throwing aerosols
into fires. The backyard incinerator or burn barrel, the
inside fireplace, a pile of burning leaves or refuse fires
can all quickly overheat aerosols and cause them to rup-
ture. Representative pressure ranges for dome ever-
sion, bottom inversion and can rupture are given in
Table XXVIII, along with typical contents
temperature at the time of rupture, using an aerosol
starch with A-31 (isobutane) propellent as an example.
Pressure relief devices to protect aerosols from ther-
mal rupture have been the subject of well over 200
U.S.A. Patents over the past 30 years, and studies in
this complex area are still in progress. Most of the work
has been done by the can manufacturers, but aerosol
valves have also been an active area. Out of all this
effort, only three devices were ever commercialized;
two of them in such miniscule quantities, they can
almost be discounted. The only device of importance is
the Rim Vent Relief (RVR) can dome modification
developed about 1969 by the American Can Co. and
later licensed to other can manufacturers, including the
Continental Can Co., where it is called a Pressure
Relief Mechanism (PRM).
The very limited number of available pressure relief
devices available presently is due largely to the com-
bination of economic, aesthetic and performance
requirements that have had to be met. Some of these
are summarized as follows:
a. The cost of the safety feature must be absolutely
minimal, since the consumer will not normally
recognize it and will have essentially no interest in
the commodity if the price is out of line with that of
comparable products. Most consumers feel they
are able to handle aerosols safely and will pay
nothing extra for a safety device, since they con-
sider it unnecessary in their case.
b. The device must be essentially foolproof in its
operation. If the dispenser can still explode, the
marketer may have to suffer the legal conse-
quences of having lulled the consumer into a sense
of complacency by installing the safety mech-
anism. If, on the other hand, the dispenser may
sometimes be caused to spew out its contents
prematurely (for instance, at too low a tempera-
ture), then the marketer may have to face torts
where injured parties attempt to recover damages
to property. This is especially worrisome now that
about 90% of all aerosols contain hydrocarbon
gases fully capable of causing detonations, if they
escape and ignite in closed areas.
c. The safety device must not look unsightly or
otherwise interfere with the saleability of the
product.
d. The device must not interfere with the assembly
or operation of the aerosol package.
e. As a part of the economic consideration, the
device must not force the canmaker to use extra-
heavy plate, conduct many extra quality
assurance tests, slow down the speed of his pro-
duction lines or do anything else that would in-
crease the price of the empty can. If integrated
with an aerosol valve, the same concepts apply.
f. The mechanism must not act to reduce the quality
or performance standard of the finished unit.
g. The safety device should work (ideally) on all
types of aerosol dispensers.
h. The unit should shut off (again ideally) the
discharge of product when the pressure is reduced
to safe levels.
As it turns out, the device that is the most promising
by far is the RVR type construction. This unit meets an
average of five of the eight criteria. The pragmatic
overall rating is about 75%, or perhaps 80%, if only
tinplate three-piece cans are considered. Because of
these aspects, the safety feature is now used on only 4 or
5% of all aerosols made in the U.S.A.
The earliest safety feature was a fusible plug of
Lipowitz' Alloy, melting point 16O0F (710C), or some
other solder composition set into the.floor of the valve
cup. Due to unreliability, inadequate discharge rates,
cost and other factors this attribute has been almost
totally discarded.
Perhaps the next important innovation was the
hardened steel spike, developed in the mid-1960s by
Cornell Aeronautical Institute at government sugges-
tions. The final system involved poising a sharp spike
directly above the countersink trench of the dome on
three-piece cans so that, when excessive pressure
caused dome eversion, the spike would puncture the
metal and release the overheated product. In practice,
the spike was very unsightly. In operation, it filled up
most of the hole it punctured in the dome, allowing
rather slow release of the can contents; so slow in fact,
that many cans could be exploded by continued
heating, even though the pressure relief mechanism
was operating.
 The "Beard Clip", which is really a modified spike,
was developed by Walter C. Beard in the late 1960s.
This hardened steel, U-shaped little accoutrement
could be literally clipped onto the top double seam and
could be expected to gouge a big hole in the dome when
that section everted under excessive product pressure.
It was somewhat unsightly and a bit costly as well.
Modified clips were designed for use along the bottom
double seam, but in this case at least three were needed
or the can would be off-balance. The various "Beard
Clips" saw almost no use in production of aerosols.
About 1970 the now defunct Sterigard Corp. (in
California) developed a rather expensive "Safti-Pac"
valve spout, designed to vent cans when the pressure
increased high enough to overcome the tension on a
sealing spring. It never moved into production. Even
now, in 1981, work is progressing in at least two loca-
tions with the aim of creating a double-acting, pressure
relief aerosol valve at a minimum upcharge.
During 1968 and 1969 the American Can Company
performed the major portion of their development work
at Barrington, IL on what is still the only viable method
for preventing the bursting of overheated three-piece
aerosol cans. It involves the incorporation of a pressure
activated safety feature, the Rim Vent Release (RVR),
into the top portion of the top double seam. In the
original design, a typical 211-diameter can dome is
made with twelve radial scorelines, about 1A " (6.4 mm)
long and evenly spaced around the periphery. Those
scorings are made in a press, where a die squeezes the
dome metal down to a prescribed thickness in each of
the indentations. The seaming elastometer is then
flowed in and cured, after which the completed dome is
Figure 48. Original
Version of RVR
Aerosol Can
American Can Company
introduced the Rim Vent
Release (RVR) aerosol can
in the 1960s. The single
indentations are now
replaced with triplet inden-
tations for better control.
seamed to the can body under carefully regulated
conditions.
After a period of a few years American Can Com-
pany determined that the pressing of slightly smaller,
shorter and shallower indentations on either side of the
single previous one acted to control the temper due to
metal working and made the mechanism more reliable.
Safety device cans produced by American Can Com-
pany and their licensees still display this triple indenta-
tion design.
When the RVR-type aerosol can is overpressurized
the dome everts. Metal movement at the top double
seam area allows the scorelines to crack open to form
narrow, lense-like apertures, through which the prod-
uct can exit rapidly. Leakage may occur even before
total eversion takes place, usually at one or two loca-
tions, but if the pressure can still rise another 5 psi (35
kPa) or so, then total eversion will occur and all the cen-
tral indentations can be expected to open and release
either gas or product.
The RVR-type containers appear to offer safe ven-
ting of three-piece aerosol cans under all situations,
except those that involve direct misuse in violation of
precautionary labeling instructions. During the 1970s a
frequent complaint was that commercially empty cans,
thrown into a fire, might undergo soldered side seam
softening and rupture at that area before the internal
pressure became high enough to cause dome eversion
and RVR release of the product still in the can. In a
very hot fire, some relatively full cans might build up
pressure faster than could be discharged through the
dome apertures, in which case the dispenser might
explode. With the swing from solder to welded cans, the
first problem is eliminated. The second one was investi-
gated in 1980 and 1981 and found to be extremely rare.
Problems that still exist are as follows:
a. Cans will spew out their entire contents at the time
of dome eversion, which will happen in the field
with far greater frequency than rupture due to the
much lower pressure (or temperature) required.
Such things as pigments, strong solvents and
flammable hydrocarbon propellents can then br-
ing about secondary damage.
b. The score lines on the dome are very visible and
may show rusting if the can is stored in a moist
environment. The newer, triple-scored domes
have been viewed as an attractive embelleshment
by some persons. The scorings are more visible in
 the case of white enamelled domes, least for dark
gold lacquered domes.
c. The safety feature may dilute the intent of precau-
tionary labeling. The can companies have
developed suitable alternate formats.
d. The development is limited to three-piece
containers.
e. Can costs are increased about 1%.
f. RVR-type cans are significantly more hazardous
in a warehouse fire than placebo cans. Cans do
not fly around, but anhydrous escaping product
from a multitude of cans produces a large, ex-
tremely hot fire, capable of producing structural
damage to roof areas within a short time period.
g. In a situation where some aerosols are the RVR-
type and others are not, the consumer may not be
able to differentiate between the two and think he
has an "explosion-proof can, when in fact he
does not. He might then take certain liberties in
terms of storage or disposal that could cause the
can to explode.
h. Wide acceptance of the RVR-type can could
impose very heavy costs on the canmakers, by
forcing them to add a complex operation to each
of their dome-forming lines.
i. Wide use of the RVR-type system would put
aluminum cans and glass aerosols at a marketing
and product liability disadvantage, since it works
only for three-piece units.
j. RVR-type cans undergo dome eversion and
product discharge within the 175 to 205 psig (1.21
to 1.41 MPa) range, whereas no aerosol can will
normally burst below 220 psig (1.52 MPa). To
compensate for this and reduce the statistical
chance of product release under very warm
storage conditions, the marketer must often
choose between the use of a lower pressure for-
mulation and a higher strength container—such
as the DOT Specification 2P type.
At least one government has recognized officially the
safety aspect of RVR-type aerosols. In regulations
effective during 1972, Canada required that a bursting
symbol be prominently displayed on the front panel of
aerosols to warn the user of its potential hazard.
However, if the dispenser has an approved safety device
designed to prevent bursting, they agreed that the
onerous symbol could be omitted.
Marketer acceptance of the RVR-type container has
been indifferent. Probably no more than about 100
million have been made in any year since they were
introduced about 1970, and the number seems to be
decreasing at the start of the 1980s. Rationales by
marketers for using the special cans vary: dedication to
safety, concerns about product liability actions, promo-
tional campaign (for a direct selling or "wagon trade"
concern), want the best possible product in every way,
and so forth. The precautionary statement "Do not
incinerate." should be retained on RVR-type cans,
since long jets of fire can be produced when the dome
section everts, at least for some formulations. These jets
can injure persons standing close to backyard burn
baskets, burn barrels and fireplace type incinerators. In
fact, with the increasing numbers of refugees, the so-
called "functional illiterates" and others with a below-
average comprehension of the English language, some
marketers are talking about revising the statement to
"Do not incinerate or burn.'' (Even though the English
word "incinerate" is closely related to the Spanish
"incineradar".)
Compartmented Aerosol Cans
A number of compartmented aerosol containers are
available. They are considered under two headings:
those where the can is prefitted with a piston, inner
cylinder or bag, and those where the compartment is
introduced as an extension of the valve. Only the first
variety is considered here.
Perhaps the earliest piston can is the American Can
Company's "Mira-flo" aluminum 6-oz. container,
introduced in the early 1960s. The container itself is
their "Mira-spra" 202 x 406 can, containing a plastic
piston and a base section pierced with a small hole. The
piston is made usually from a particular polyethylene
alloy. The skirt is about 1.5" (38 mm) long and is
designed that way to minimize "blow-by" of lower
viscosity products, to prevent possible tilting and to
Figure 49. Base section of aluminum monobloc can
flared inner portion of the rubber plug showing
negate the effects of small body wall dents, which might
otherwise allow the gas to slip past the piston and form
bubbles in the product itself. See Figure 51.
During the early years the sales of "Mira-flo" cans
were inhibited because of the difficulty of gassing the
can through the bottom Vs" (3.2 mm) hole and then
plugging it under sealed-system conditions with the end
of a reel of rubber rod about %4 "(3.6 mm) in diameter.
Complex laboratory scale devices were produced by the
canmaker, and finally some production size gasser-
pluggers were developed. After that, sales began to rise.
During the early 1970s, a modification of the European
Varnley Valve was developed in order to simplify the
gassing process, but nearly all "Mira-flo" cans are still
gasser-plugged.
The combined sales volume of the "Mira-spra" and
"Mira-flo" cans totals about 30 million units per year
from American Can Company's plant at Regency, PA.
However, since there are only two major marketers
using the "Mira-flo" can, information on the sales
volume of this particular unit would be too revealing of
the marketer's sales.
The "Mira-flo" dispenser is useful only with prod-
ucts within a certain viscosity range, generally about
10,000 to 500,000 cps., as measured at room temper-
ature, using a Brookfield Model RVT Viscosimeter
with Spindle No. 7 at 10 rpm. Since nearly all the possi-
ble products are non-Newtonian fluids, the conditions
of measurement have to be delineated for reproduce-
ability. A variety of cheese spreads and cake toppings
are currently marketed in the "Mira-flo" unit. Many
other products are possible as well, such as hand
lotions, petrolatums, mayonnaise and toothpastes. On
the other hand, certain likely candidates have failed,
such as peanut butters, where most compositions
undergo syneresis under pressure, with the vegetable
oil separating slowly at the top and leaving an excep-
tionally high viscosity peanut grind as the lower
stratum.
Figure 50. Polyethylene
piston used in "Mira-flo"
aerosol can. The
diameter is about 2.00"
(51 mm).
Historically, the only other piston can has been
American Can Company's "Flo-Master" container, a
drawn 211 x 413 tinplate can that was introduced about
1969 and discontinued after several years because of
disappointing sales, plus the Pepo unit, described later
in this chapter.
The Sepro-Can
The Continental Can Co. introduced their "Sepro-
Can" development about 1967, with the thought that it
would expand significantly the aerosol industry by
adapting the aerosol principle to permit the dispensing
of higher viscosity products; e.g. those in the 10,000 to
2,000,000 cps. range, measured with a Brookfield
RVT at S.#7 and 10 rpm. under ambient conditions.
The first units consisted of a 202 x 406 can with an
interior plastic bag of either modified polyethylene or
"Conoloy", a special plastic alloy of relatively low
permeation rate. The side walls were pleated, like an
accordion, so the bag could collapse upward as the con-
tainer was emptied. The top of the bag curled out-
wards, fitting neatly over the can bead. The can itself
was rather routine, except that the plug diameter of the
usual one-inch (25.4 mm) opening was expanded to
about 1.025 " (26.0 mm) in order to make room for the
plastic bag. Also, a Vs" (3.2 mm) hole was punched
through the center of the bottom to allow for gassing
and plugging. "Sepro-Cans" sold for a premium of
about 55% over the cost of the non-compartmented can
of the same size. A typical "Sepro-Can" of 1970 is
shown in Figure 52.
During the first few years several changes were made
in the bag contour, giving it a more wavey or "sine-
curved" profile, since the original sharp pleats often
caused gas voids when the concentrates were added.
When the gas bubbles emerged during actuation, they
expanded with sharp splats, sometimes spattering the
product in the process. The company also added a
202 x 509 can size and a 202 x 200 sample can. They
also produced samples of "Sepro-Cans" in the
211 x 604 container, but no market ever developed.
The 202 x 509 dispenser eventually became the most
common size by far. In this case, the bag capacity is
about 7.02 fl. oz. (207.6 ml) with the valve in place. An
additional 1 or 2 % of product can be filled if the concen-
trate is added at temperatures of about 4O0F (4.40C),
depending upon the thermal expansion coefficient of
the product.
At room temperatures, the capacity of the bag for the
202 x 509 can is about 74% as large as the overall can
capacity of 9.71 fl. oz. (287 ml). This compares rather
favorably with the average aerosol fill of about 85 % of
can capacity, especially when the liquid hydrocarbon
propellent outside the bag is also included. In terms of
volume fill, the penalties for using "Sepro-Cans" is a
small reduction in fill size, and the fact that the net
weight will have to relate to one bag-full of the product.
It is impossible to overfill a bag without spilling the
excess, and underfilled bags have the spattering effect
mentioned earlier. The net weight of "Sepro-Cans"
must now relate to the weight of concentrate that can be
dispensed from the bag, about 96 to 98% of the weight
in the lowest net weight bag in twenty representative
samples. According to NBS Handbook No. 113, pub-
lished in 1981, there is no longer a weight allowance of
about V8 oz. (3.5 g) to compensate for the difference in
results of the fast discharge test method and the slow
discharge process used by the average consumer. The
allowance has been retained only for foam aerosols. As
such, it probably cannot be considered to apply to the
gelled (post-emergent foaming) shave creams that now Figure 51. A typical early "Sepro-Can" made by the
Continental Can Company in 19/0.
form the bulk of the "Sepro-Can" filling business.
The inner bag of the "Sepro-Can" is a one-ply structure. Shown at right
A major potential problem with "Sepro-Cans" is a cross-section of the system. Compatibility of product with the
plastic bag must be considered when developing product formula.
and, in fact, with all plastic bag-in-can dispensers is the
phenomenon of permeation. Permeation takes place
when significant numbers of molecules pass through a methylene chloride, dimethyl ether and certain per-
barrier during a fixed time period. Larger molecules fume aldehydes should be tested thoroughly before
permeate more slowly than small ones. More permea- approval. Carbon dioxide, nitrous oxide and even com-
tion takes place at higher propellent pressures, simply pressed air have been suggested for " Sepro-Can"
because there are more molecules in contact with the systems, but they have the distinct shortcoming of
barrier. Molecules with higher solvency ratings tend to having no liquid reserve to draw upon. Thus, the pro-
pass through more effectively than inert types. The pellent pressure decreases markedly during use. As an
gross effect of permeation is that "Sepro-Can" concen- ancillary consideration, there is also no reserve against
trates tend to become slightly aerated upon aging. slow or latent seepage, either through the bag or
Ingredients in the concentrate may also pass through through the can itself.
the bag into the propellent phase. For example, acetic Even after some 14 years, the "Sepro-Can" inner
acid in a packed mayonaisse product seeped through bag is still a one-ply or non-laminate structure. Efforts
the bag and severely attacked the unlined can, causing have been made to coat the bag with films of Mylar or
perforations. other plastics having very low permeation, but the
P-114 (sym-dichlorotetrafluoroethane) is perhaps the engineering problems have been too intense for a prac-
ideal propellent for slow permeation performance. It is tical solution.
a large molecule, with very slow solvent powers. The Gassing has always been a general problem with
fluorocarbons P-115 (monochloropentafluoroethane) "Sepro-Cans". Special equipment is needed. The
and Freon C-318 (perfluorocyclobutane) offer com- earliest versions required a gasser-plugger, which
parable peformance but are very high priced. The tended to restrict filling to only a few contract fillers who
smaller P-12 molecule permeates bag walls somewhat had the needed engineering skills to develop such a pro-
more rapidly, and the regular hydrocarbon gases (pro- duction device. Then, in the early 1970s, the cans were
pane, isobutane and n-butane) more rapidly yet. In introduced with the Nicholson Model 55-18 valve
most cases, strong solvents permeate too fast to be used. (fashioned rather like a football or basketball valve) that
As a result, P-Il (trichloromonofluoromethane), fitted through a somewhat enlarged hole in the can
bottom. It accepted both liquid and gaseous propellents
at very high rates, allowing single-head gassing stations
to operate at up to 30 cpm. For still higher speeds the
rotary Kartridg-Pak "Under-the-Cap" (U-t-C) could
be used by adding a special gassing head under the
elevator plates. However, a major problem with the
original Nicholson valve was that exact positioning of
the gassing tube under the center of the valve was
required to avoid tilting or otherwise distorting the
valve stem, causing either immediate or latent leakage
of the propellent liquid. To correct this problem a
special, solid rubber plug was developed by Continen-
tal Can Co., first used commercially about 1971. It is
known as the Nicholson No. 2 valve. This inexpensive,
one-piece fitment is technically a rubber billet, partly
splined vertically on the side wall, and stuffed part way
into the hole in the bottom of the can by the can maker.
The filler then uses special equipment to force pro-
pellent past the splined slots and into the exo-space
Figure 52. Kartridg Pale's "Sepro-Can" Unit for Under-
the-Cap (U-t-C) Gassing
(between bag and container), after which a small ram
forces the valve further into the can until the splined
portion is totally inside and a gas-tight plug is produced.
Additional U-t-C change-over parts were necessary to
convert the machines to the revised plug. The conver-
sion unit is shown in Figure 53.
The "Sepro-Can" is well suited for the dispensing of
relatively viscous products, those in the range of
2,000,000 cps. at room temperatures. Both Newtonian
and non-Newtonian types can be handled. While there
is no difficulty in dispensing low viscosity products (up
to 10,000 cps.), as a rule these types can be handled in
the lower cost standard aerosol packages. "Sepro-
Cans" have been tested with regular, low-viscosity
shaving cream emulsions. The standard aerosol
package produces a heavy, wet, slighty runny foam
near the end, due to propellent loss from the emulsion
into the enlarging head space. With the "Sepro-Can"
this modest problem is eliminated. On the practical
side, it has not been enough of a problem to justify the
added packaging cost of using a compartmented can.
Even a metered foam product would become only
about 1.5% more concentrated near the end of the can,
so that "Sepro-Can" packaging cannot reasonably be
justified for pharmaceutical or dosage-type foam prod-
ucts any more than for shave cream types.
A single exception is the gel-type shaving cream. In
products on the U.S.A. market in 1981 offered by two
major marketers and being developed by others, the
gelled concentrate contains a few per cent of isopen-
tane. This propellent has a boiling point of 860F
(3O0C), so that then the gel is worked or slightly
warmed, it blossoms into an elegant, highly lubricious
foam structure.
If the isopentane is to be incorporated into the gel
during the batchmaking process, it is necessary to pro-
duce it under cold conditions, such as 4O0F (4.50C), in
order to prevent the inadvertant generation of foam at
that point. Spin fillers are then used to transfer the con-
centrate gel to the fluted bags, for instance a Con-
solidated Packaging Machinery Corp. 18-head Spin
Filler or various Elgin Packaging Machinery Corp.
models. The containers can be twirled around at from
about 400 to 1200 rpm, in order to facilitate getting the
product into the plastic flutes without air entrapment.
However, if the spinning rate is excessive, a vortex will
develop in the center. Optimum spin speeds must be
developed according to the properties of each concen-
trate.
 During 1981, some 30 million "Sepro-Cans" were
produced in the U.S.A. Nearly all of this volume was
dedicated to the latent foam gel shave cream products,
but other items of a cosmetic nature were filled as well.
The cans were gassed using two Kartridg-Pak Co. 9
head U-t-C fillers (modified), three Terco, Inc. Sepro
Chargers (40 cpm capacity), and at least three custom-
built machines of limited throughput. As an indication
of cost, the Terco device runs about $14,000 complete,
for the 202-diameter cans.
Products that have been commercially packed in the
"Sepro-Can" include a moisturizing cream, depilatory
cream, shaving gels (for both men and women), caulk-
ing compounds, a tomato catsup, natural honey, tooth-
pastes and an interesting ablative gel designed to
thermally protect precious ringstones during resizing of
the band. A number of products have also been con-
sidered, for instance, such food type items as chocolate
syrup, ice cream toppings, soft drink super-concen-
trates (good for up to 100 8-oz. drinks), maple syrups,
jellies, and mayonnaise. But the concept of an expen-
sive container that did nothing but dispense the stand-
ard produce proved uninspiring to consumer test
panels, and the projects were dropped in every
instance.
The Presspack System
During 1978, the Presspack Corp. of Bronxville, NY
combined forces with the Southern Can Co. to intro-
duce their new Presspack System to the aerosol
industry. An interesting "Doubleheader" package was
offered. It consisted of a double necked-in 202 x 509
"Slim-Look" can with Southern's "Aeroweld Super
Seam" construction. Each end was fitted with a can
dome, measuring a 1.998 ± 0.004" (50.75 ± 0.10
mm) across the double seams. Two specially shaped
translucent polyethylene bags had been inserted into
the can body before end seaming, and after the ends
were attached, the flared lip of each bag was pulled
through the one-inch (24.5 mm) opening. The cut edge
at the top had an average diameter of about 1.160"
(29.5 mm), allowing it to hug the can bead at least as far
out as the crown area. The bags had a neck finish thick-
ness of about 0.012 " (0.53 mm) and this required the
can domes to have a plug inside diameter of about
1.048" (26.6 mm) and an outside bead diameter of
about 1.242 " (31.5 mm). The bags varied in thickness
from about 0.028 " (0.71 mm) at the throat to as thin as
0.009 " (0.23 mm) at the body wall bulges. They had a
capacity of about 4 fl. oz. (118 ml) and each was filled
with a different cosmetic product.
To insure a gas tight seal between the can and the
0.14" (0.35 mm) thick lined aluminum cups, a stand-
ard 0.040 " (1.00 mm) thick rubber cut gasket is placed
over the can bead before crimping. Crimp dimensions
of 1.070 " (27.18 mm) diameter and 0.190 " (4.83 mm)
depth were recommended. The use of valves with
GK-45 or similar flowed-in gaskets was specifically not
recommended, since the typical 0.22" (0.56 mm)
elastometer thickness is insufficient to bridge the 0.015 "
(0.38 mm) step between gasket and can bead at the
outer rim of the polyethylene bag flange in order to
create an effective secondary seal.
The "Doubleheader" unit was principally designed
as a sales give-away product, and had little or no com-
mercial significance. The regular unit looks much like a
regular 202 x 509 can, and normally has a single shell,
full diameter Risdon Corp. cover cap to complete the
cylindrical appearance.
In cooperation with Kartridg-Pak, the Presspack
Corp. has developed recommended gasser adjustments
to convert for the U-t-C gassing of their "Presspack"
barrier units. Either a compressed gas at the desired
pressure of 115 psig (793 kPa) or so, or about 2.5 to 3.0
g of a hydrocarbon propellent may be used as the pro-
pellent. For example, for the addition of a liquified
propellent by either the in-line or rotary U-t-C equip-
ment, the following steps must be undertaken:
a. Relax collet pre-set adjustment
b. Replace pressure pad spring with solid washers or
stops to give negative inner bell lift.
c. Set head in fill posiiton with a K " (8.3 mm)
spacer under can to be filled. (No valve in can.)
d. Set for propellent charge of about 2.5 g and pro-
pellent pressure of about 400 psig (2.76 MPa).
e. To allow for dwell time in filling cycle, reset
vacuum timer to operate during the fill cycle. (In-
line machines only.)
f. Set for crimp diameter of 1.070 " (27.18 mm) and
crimp depth of 0.190" (4.83 mm). Use standard
molded cap seal. Prefer undimpled valves.
The "Presspack" dispenser is said to be thoroughly
researched and proved out in terms of millions of cans
produced commercially with at least 25 product types.
Nitrogen or compressed air propellents are preferred.
Such forms as pure liquids, pastes, gels, foams and

Figure 53. Bag-in-Can
System Offered in
Europe
A "Compak" depilatory
container, illustrating the
bag-in-can system offered
by Aerosol Service AG,
Switzerland. The design is
contrived to give the cylin-
drical container the
appearance of being
contoured.
creams can be dispensed with the container held in any
position. Emptying efficiency is up to 99% of the bag
contents. There is a slow permeation of the bag material
by various propellents, and this may cause some aera-
tion of the dispensed products.
The Alupresspack System
Starting about 1978 a European development took
place, with the creation of a barrier pack startingly
similar to the U.S.A. "Presspack" development. The
Bag capacity 463 ml. with valve
inserted.
Aluminum can diameter: 65 mm.
Dimensions are typical. They are not
to be used for specification development.
Figure 54. Polyethylene Bag for Alupress-Pack Can
European system provides for the exclusive use of an
aluminum Monobloc aerosol can in the 1.575" (40
mm) to 2.559 " (60 mm) diameter range and the provi-
sion for adding the propellent through a hole in the can
base, which is then sealed with a rubber plug. The
invention is being successfully marketed by Aerosol
Services, S.A. of Mohlen, Switzerland.
The range of product sizes is from about 100 to 500
ml. In a typical product, a disinfectant spray is
marketed with the formulation:
350 ml in a polyethylene bag:
80.00% Ethanol96v.%
0.40% Formalin (37% HCHO in water -
inhibited; DAB 7)
0.01% Alkyldimethylbenzylammonium
chloride 90%
0.03% Glyoxal (40% C3H4O2 in water -
inhibited)
0.01% Oligo-di(iminoimidocarbonyl) imino-
hexamethylene 20%
0.05% Perfume
19.50% De-ionized Water
In the surrounding 65 x212 (628 ml) aluminum
can:
12.0% ± 2.Og propellent.
The spray is soundless and the dispenser can be
operated from any position. There is no significant
change in delivery rate during the life of the package. A
sketch of the polyethylene bag is provided in Figure 51.
The Microcompack and Alucompack Systems
Both of these recent developments took place in
Europe and are being marketed in the early 1980s by
Aerosol Services, S.A., Switzerland. The "Microcom-
pack" system utilizes an aluminum tube in the 5 to 15
ml range, fitted with a heat-softened, thin aluminum
inner tube (cylindrical, with a flat base) that slides into
the can rather snugly through the 20 mm opening. The
diameter of the inner container is thus about 14.0 mm.
It is flat-flanged at the top and seals against the beaded
can opening with the aid of a cut rubber gasket that is
only about 0.012 " (0.3 mm) thick.
In the production operation, the inner container is
filled with the product to within a short distance of the
flanged top. The 20 mm aerosol valve, with a large-
diameter plastic body, is fitted into the top of the tube,
where the body acts as a sealing plug. Mean while, the
empty can is filled with a few grams of extremely cold,
Figure 55. The Alu-Compack Composite Aerosol System
This system is marketed by Aerosol Service, A.G. The illustration
shows aluminum cans with and without base plugs, and how the
aluminum inner tube collapses rather completely as the unit is
dispensed. Both spray and foam type actuators are shown.
Figure 56. Bag-in-Can Development from Switzerland
A unique bag-in-can development, where the special polyethylene
alloy container is inserted into an aluminum can, filled with product
and attached to the special valve assembly. Hydrocarbon propellent
is injected and the valve crimped into place. (Aerosol Service, A.G.)

liquid propellent. The inner container is slipped quickly packaging it in an attractive shadow box. The unit is
in place and the 20 mm valve ferrule clinched to the designed to stand upright, and obviously avoids the
can, making a hermetic seal. various problems inherent in the conventional tube,
This dispenser has been commercialized in Europe such as unsightliness and the need to roll it up during
during 1980, using both hydrocarbon and chlorofluoro- use. Marketers in the U.S.A. are studying this impor-
carbon propellents — and possibly dimethyl ether. But tant innovation. They were unsuccessful in the case of
in the U.S. A. a major stumbling block is the addition of the "nitrosol" Crown 202 x 411 cans of the 1960s, and
highly flammable hydrocarbon liquid to an open con- have seemingly been disenchanted in the "Sepro-Can"
tainer. A closed system gassing method is now available toothpastes marketed in small volumes during the
in Europe because of this problem. They gas the outer 1970s. Aside from cost considerations, the toothpaste
tube with the inner one about half-way inserted and
then make the crimped or clinched seal under closed Figure 57. Alucompack System for Toothpaste Product
system conditions. A sophisticated dispenser of toothpaste, marketed in West Germany
The larger "Alucompack" system is designed along by Blendax. A vertical slit in the plastic actuator opens to dispense
the paste when pushed sideways, then closes to prevent hardening
the same lines as the "Microcompack" version, but or other exposure effects.
uses aluminum cans in the 30 to 35 mm diameter
range, with standard one-inch (25.4 mm) opening. The
inner tube or "Alu-bag" of heat-killed aluminum may
now be about 0.992 ± 0.003" (25.2 ± 0.08 mm) in
outer diameter, and again, may be only about ^"(12.7
mm) shorter than the outer container. After filling with
product, the inner tube is plugged with the mounting
cup of the valve. An exploded view of the overall
assembly is shown in Figure 59, in this case relating to a
very unusual application. Most of these units are fitted
with regular spray, paste or foam valves and are used
for various pharmaceuticals and toiletry products. In
the early 1980s a large toothpaste marketer has intro-
duced one of his products in an "Alucompack" dispen-
ser measuring about 1.2 " x 6.0 " long (30 x 152 mm),

Valve assembly
Thin lathe-cut rubber gasket
Inner "Alu-bag"
Aluminum Monobloc tube, 1.25"
(32 Tm-n) in diameter and 6.50"
(165 mm) long.
Thickness of valve cup and
aluminum outer tube are
exaggerated to emphasize
thin "Alu-bag" component.
Figure 58. Cross-Section of Alucompack Dispenser
(Exploded view, showing typical valve.)
Figure 59. Coating, Filling and Use of "Flip" Barrier Pack Cans Courtesy of Tor Petterson, I.D.S.A.
COAT FILL
"of the 1980s'' in "Alucompack" form may capture
their interest. One highly intriguing aspect of the Ger-
man product is the use of a dispensing tube that is
rounded at the end, rather like a bullet-shape, and then
slit longitudinally for a short ways. Upon actuation, the
slit opens to provide the product, but when the toggle-
action valve is released the slit closes tightly, keeping the
toothpaste clean, soft and ready for the next use.
The FLIP System
The FLIP (Formed Liner In Place) aerosol system
was developed by Dr. Tor Petterson, a professional
inventor at Rancho Palos Verdes, CA, with patents
issued and/or pending in several countries. The aerosol
can is first sprayed or dipped to coat the interior with
controlled release coating, such as a polyethylene/
acrylonitrile laminate, vinyl acetate/polyethylene/
polyimide laminate or acrylate/polyvinyl chloride com-
position. For three piece cans this operation is best per-
formed before attaching the dome section. A base is
used that is fitted with a gassing aperture, preferably
using a gassing plug of the type now used for "Sepro-
cans".
As shown in Figure 60, the container is filled with
product, sealed with a suitable valve and then gassed
through the base. At least 30 ml of head space should be
left in the can when filling the concentrate to allow for
the later addition of propellent and also leave some
CHARGE USE EMPTY
space to take up any thermal expansions of product and
gas that might occur prior to consumer use.
When the dispenser is first used, the head space air is
emitted quickly with a sharp crackling sound. After this
the product emerges. As it does, the lower section of the
can liner separates from the can wall and folds upward.
Since it is only about 0.002" to 0.008" (0.05 to 0.20
mm) thick, progressive upward folding is not a prob-
lem. When the dispenser is commercially empty the lin-
ing will have folded to about mid-point of the can wall,
as shown.
The dispenser has been tested using propellent
pressures of from 25 to 90 psig (172 to 620 kPa) with
chlorofluorocarbon, hydrocarbon and compressed gas
(CQz and N2O) propellents. Products such as pre-
foamed shaving cream, toothpaste, skin cream, cough
medicine and a caulking compound have all been tested
satisfactorily for over two years. The dispenser will
discharge at least 95% of viscous materials and a
minimum of 97% of low viscosity liquids. Only about 4
to 10% of the inner coating is exposed to the propellent
prior to consumer use. In addition, most coatings are
laminates, so that permeation of propellent into the
product is negligible. The system is being commer-
cialized in Germany under a European license.
The Enviro-Spray System
The final barrier pack to be discussed in some detail
is the. "Enviro-Spray", developed by inventor Ellis
Reyner during the 1960s and taken over by Grow
Group, Inc., Montgomeryville, PA, about 1977. After
a long and costly refinement program, Grow Group
introduced their first consumer product, "Like Magic''
Plant Spray during 1981 and also offered samples to
interested marketers.
The product is prepared using a special barrier pack
that is dropped into the empty aerosol can before filling
with concentrate and sealing with the valve. A com-
bination of citric acid and sodium bicarbonate (or
similar chemicals) is used to generate slowly gaseous
carbon dioxide in the can, raising it to a pressure suffi-
cient for efficient dispensing action. The gas remains
within the expanded bag and does not mix with the
product. As the product is dispensed, the bag becomes
still larger, rupturing an inner wall and releasing more
• chemical to form additional gas. This may occur several
times during the life of the can, so that the gas pressure
within the unit can remain reasonably uniform during
use. The plastic pouch and its contents may weigh to 1
oz. (28 g) for a 16 oz. (454 g) fill. The dispenser is
claimed to deliver 98% of its contents. For further
information, refer to U.S. Patent No. 3,718,236 or
Enviro-Spray Systems, Inc. at Montgomeryville, PA.
Other Barrier Packs
Around 1980 Boxal/Alusuisse introduced their
"Compack" unit, representing a new type of barrier
system where the gassing operation can be performed
by forcing the propellent into the container between can
neck and valve cup. This eliminates the need for a
punctured can base and special gasser-plugger type
operation. The plastic inner bag is secured to the valve
tailpiece via a special polyethylene adapter. Either
bubble or ridged sidewall plastic bags can be used and
the unit can be adapted to all standard containers with a
standard one inch (25.4 mm) opening. The bag must be
the correct length for the can, since a preliminary inter-
fit with the adapter is required before U-t-C gassing. At
the time of gassing the pneumatic pressure forces the
top section of the bag fully into the circular slot in the
adapter producing a barbed, hermetic seal between
valve and bag.
During the late 1970s inventors Th. & H.
Schumacker developed the "Pepo" ecological aerosol
and formed S.A. Kervil, N.V. to promote the
dispenser. The firm is located in Brussels, Belgium.
The unit is a piston type, similar to American Can
Company's "Mira-flo" container. The piston is
somewhat unique in that it has five fins that wipe
against the can wall. Fins two and three (from the
bottom) have a diameter of typically 2.065 " (52.45 mm)
and are very thin, so they can bend against the body
wall. The bottom fin is typically 2.051 " (52.10 mm) and
the two uppermost fins are each typically 2,039 " (51.80
mm). They are there to keep the 1.940 " (49.28 mm) tall
piston aligned vertically so that the two wider, sweeping
Figure 60. Piston used in
the "Pepo" ecological
aerosol container pro-
moted by S.A. Kervil
NV, Brussels, Belgium

PROPELLANT VAPOR
VACUUM
AND
"ROOUCT DISPENSED
FORMEOAT
THIS POINT
PR VAPOR
PHASE
PROPELLANT
E PREVAL- SPRAYMAKER
V LIQUID
PROPELLANT
t
POWER UNIT
INTERNAL
TUBING
SCREW CAP
(COUPLING)
D I P TUBE
PRODUCT
CONTAINER
PRODUCT
STRAINER
Figure 61. The "Preval" Spraymaker
fins can act to separate gas and product portions. The
second thin fin is also insurance against the co-mingling
of phases, if the can wall has a slight dent that would
distort one of the fins but not the other concurrently.
The piston has a well in the top to accommodate the
valve body. Samples are shown with a Boxal can and
Valois valve. The propellent is compressed air,
although liquified propellents should work even better,
since they would maintain a constant pressure through-
out package life. The propellent is injected via a gasser-
plugger operation. Concentrates of the water-base and
hydroalcoholic base have been tested successfully and
other, non-warping types would seem reasonable
candidates.
The original "Preval" unit was introduced by the
Precision Valve Corp. in 1965. The propellent in a
power unit, typically a lithographed l 3 / 8 " x 6 "(35 152
mm) aluminum tube, is used to aspirate product out of
a separate container. After some disappointing initial
results with filled products, which were able to leak out
of the dip tube connecting them to the "Preval" valve,
Precision Valve Corp. decided to sell only the dispenser
with the product container empty. In the present form,
a nominal 4 fl. oz. (118 ml) glass wide-mouth jar is used
to contain the product. The black plastic screw cap is
fitted with the "Preval'' power unit, so that pressing the
valve button creates a 99% vacuum in the valve, caus-
ing the product to flow up the common dip tube, be
mixed with the emitted gaseous propellent and be
discharged as a spray. The original dispensers con-
tained P-12, but in the U.S.A. these have had to be
revised to a hydrocarbon propellent with a consequent
drastic reduction of filling weight to about 3 oz. (85 g)
and some loss of capacity. At a typical dispensing ratio
of about ten parts product to one part propellent, some
30 oz. (850 g) of paint, lubricating oil, cutting oil,
sealants and other products can be handled during the
life of the unit. The manufacturer sells a fair number of
"Prevals" each year, mainly in retail outlets such as
hardware and automotive supply stores.
The final "barrier pack" is not really a composite
aerosol but is included for completeness. In the early
1970s, Plant Industries, Inc. introduced their SeIvac
Division's "Selvac" dispenser, consisting of a posted
heavy rubberized bag mounted within a formed can,
plastic bottle or other rigid container. The bag was
closed at the top with an aerosol valve, after which
product was injected to fill the unit. In the unfilled
form, the bag had an internal volume of only a few ml
and when distended with (for instance) a pint (473 ml)
of product, the resiliency factor caused it to exert a con-
siderable pressure on the contents. This pressure was
utilized to dispense the material. Some hand lotions and
related products have been packed commercially using
the "Selvac" system.
During late 1980, three "Selvac" experts departed
from Plant Industries, Inc. and formed Container
Industries, Inc., Londonderry, NH. In the following
year they introduced their "Exxel" elastomer package
counterpart, claiming added design simplicity and
other advantages. Several personal care and household
products were test marketed in 1981, and such products
as greases, creams, lotions, foams, gels are recom-
mended for trials. The bag is non-porous polymer and
can be manufactured from selection of several
materials.
Considering barrier packs in general, although they
have been available for perhaps 25 years or so, the
present interest seems to be on the increase. In 1981 it
reached a sales volume of about 1.5% of the total
aerosol productions of both the U.S.A. and Europe.
This should continue to grow in the decade of the 1980s.