THE AEROSOL: a little known

technology
Assumption 2

Given the exclusively educational and eminently illustrative nature

and purpose of the class explanations of this presentation, the
author is entitled to article 32 of the Intellectual Property Law in
force regarding the partial use of third-party works such as images,
graphics or other materials contained on the different slides.
Aerosol packaging 3

FIVE REASONS TO USE AEROSOLS

Aerosols offer five distinct advantages as a packaging format:

1.- No mess: Aerosols dispense product accurately and efficiently.

2.- Minimal product waste: You can use every drop of product, avoiding waste, leakage and spills.

3.- Easy of use: People tend to prefer the convenience and ability to dispense products accurately.

4.- Reliable: Aerosols perform consistently from the first spray to the vary last. They are airtight, clean and hygienic.

5.- Recyclable: Aerosols are generally made of metal and are readily recyclable.
Aerosol production worldwide 4

PRODUCTION WORLDWIDE IS ESTIMATED AT MORE THAN:

a) 1,5 billion units

b) 5 billion units

c) 10 billion units

d) 15 billion units
Aerosol definition 5

Aerosol

Suspension of fine solid or liquid particles in air or gas

EXAMPLE:

Smoke Fog
Aerosol product types 6

Aerosol types

Propellant in contact Propellant not in contact

Without propellant
with product with product

Valves BOVs Spray Pumps

 7

00 Aerosol propellants
 Aerosol propellants 8

Liquefied propellants and Compressed gasses

Liquefied Propellants Compressed Gasses

 Liquefied Petrolueum Gas (LPG)  Non soluble (compressed air and nitrogen)

 Dimethylether (DME)  Soluble (carbon dioxide and nitrous oxide)

 Halogenated Fluoro Carbons (HFC)

Aerosol propellants 9

Types of Propellants

DME HFC152a HFC134a Propane I-butane N-butane N2 Air CO2 N2O

Boiling point (°C) -25,1 -25,1 -26,1 -42,1 -12,2 -0,5 -195,8 -194,1 -78,4 -88,5

Vapour pressure (21°C) 4,3 4,3 4,9 7,5 2,1 1,2 n/a n/a 58,2 52,4

Liquid density (21°C) 0,66 0,91 1,21 0,51 0,56 0,58 0,00114 0,00129 0,713 0,913

Flammability in air (LEL) 3,3 3,9 n/a 2,2 1,8 1,9 NO NO NO NO

Flash point (°C) -41 -50 NO -104 -83 -74 NO NO NO NO

Solubility in water (%wt) 35,1 1,7 1,1 0,007 0,008 0,008 0,015 0,018 0,759 0,588

Flammability YES YES NO YES YES YES NO NO NO NO

Toxicity LOW LOW LOW LOW LOW LOW LOW LOW LOW LOW

Environmental VOC No VOC GWP VOC VOC VOC LOW LOW LOW LOW
 10

01 Aerosol forms
 Aerosol forms 11

One clear phase · Emulsion ·Suspension

ONE CLEAR PHASE EMULSION SUSPENSION

HOMOGENEUS AEROSOL SYSTEM TWO STABLE PHASES POWDER

The propellant is completely soluble Propellant and product (usually rich Powder suspended into one clear
into the product of water) are not soluble phase/homogeneus product
 12

02 How an aerosol works

How an aerosol works 13

Liquefied propellants

Propellant
vapour
Liquefied propellants are gases that exist as liquids under
pressure.
Because the aerosol is under pressure the propellant exists
mainly as a liquid, but it will also be in the head space as a
vapour.
As the product is used up as the valve is opened, some of the
liquid propellant turns to vapour and keeps the head space
full of vapour.
In this way the pressure in the can remains essentially
constant and the spray performance is maintained
throughout the life of the aerosol. Product
and liquid
propellant
How an aerosol works 14

Compressed gasses

Compressed
gas

Compressed gas propellants really only occupy the

head space above the liquid in the can.
When the aerosol valve is opened the gas “pushes” the
liquid out of the can.
The amount of gas in the headspace remains the same
but it has more space, and as a result the pressure will
drop during the life of the can.

Product
Aerosol valves 15

The valve opens when the stem is depressed into the body
and shuts off when it is released and spring back into place.
When in closed position the stem is pressed upward by a
metal spring but when a sufficient downward pressure is
applied the spring tension is overcome and the stem is
forced downward.

This serves to slide one or more horizontal stem orifice(s)

past the stem gasket and into the top of the valve housing,
which is under pressure from the aerosol product.
The pressure forces the product through the stem
orifice(s) into the vertical centre hole of the stem and out
through the valve button or spout.
How an aerosol works 16

Liquefied and Compressed propellants

Aerosol with LIQUEFIED PROPELLANT Aerosol with COMPRESSED PROPELLANT

 17

03 Valves and Actuators

Aerosol valves 18

Components

VALVE CUP: Link between can and valve.

Typically constructed from tin plated steel, chrome plated or aluminium

OUTER GASKET: This is the seal between the valve cup and the aerosol can

INNER GASKET: The ON-OFF switch. Covers the hole in the valve stem

VALVE STEM: Controls the flow. In effect, the tap through which the product flows

VALVE SPRING: Closes the valve. Usually stainless steel

VALVE HOUSING: Contains the valve stem, spring and inner gasket

DIP TUBE: Allows the liquid to enter the valve

ACTUATOR (not shown): Fits onto the valve stem

Aerosol valves 19

Materials
VALVE CUP: Plain, Clear lacquered, Gold out/Clear in lacquered tin plate
PET coated chrome plate
Micoflex and Clear lacquered aluminium

OUTER GASKET: Buna (std) and Chlorobutyl (on request)

INNER GASKET: Buna, Neoprene, Butyl and Chlorobutyl

VALVE STEM: POM and PE

1 opening 0.27, 0.30, 0.40, 0.50 and 0.60 mm
1 opening 0.50 and 0.60 for powder products
2 openings 0.50 mm std and for powder products
4 opening 0.50 mm
VALVE SPRING: Stainless steel AISI 302

VALVE HOUSING: PE and POM

DIP TUBE: PE
Aerosol actuators 20

The actuator may be a simple spray button or it may be an integral part of

various spouts or spray domes.

As a rule, it not only allows the user to operate the valve, but it may also
fulfil a major role in determining spray rate, spray pattern, particle size
distribution and so forth.
A very large array of actuator is available for dispensing sprays, foams and
other product varieties.
The actuators are almost always injection moulded from PE or PP with
components that virtually eliminate any change of cracking from stem
tension.
Aerosol actuators 21

ONE PIECE · directional without insert

Narrow cone | Long distance spray Insecticide | Dry airfreshener| Technical

Aerosol actuators 22

DIRECTIONAL TWO PIECE · with NMBU insert

Medium-Narrow cone | Medium-Long distance spray Glitters | Spot remover | Product with powder
Aerosol actuators 23

FINE MIST TWO PIECE · with MBU insert

Good nebulisation| Large cone | Short distance spray Body deodorant | Hairspray | Water based product
Aerosol actuators 24

Actuators may be specially formed and equipped with plastic insert to aid
in the development of particularly desirable spray pattern.

In general they are called MBU or mechanical break-up system.

The insert is forced into the enlarged orifice area of actuator.
The product enters a peripheral channel and then goes into at least 2 and
nearly always 4 offset radial channels placed in the insert.
The configuration acts to give the product a strong swirling action as it
leaves the actuator.
 25

04 How are aerosol filled

How are aerosol filled 26

Basic components
ACTUATOR

VALVE

An aerosol is made up of several basic components:

PROPELLANT
VAPOUR
• An aerosol can
• The product
• The propellant
• A valve with or without dip tube DIPTUBE
• An actuator
• A dust cap (not shown) CAN

These all have to be assembled, and this is achieved using automatic filling PRODUCT
machinery. AND LIQUID
PROPELLANT
How are aerosol filled 27

Filling phases

The product, usually in the form of a liquid, is

Start with an empty aerosol container.
added. This contains all the active ingredients,
This will be made of tinplate or aluminium.
except for the propellant.
Empty can Add product

The propellant is injected under pressure,

through the valve. The propellant may be in the
form of a liquefied or a compressed gas.
The Aerosol valve is fitted and crimped to the
If a liquefied gas is used it will exist as both a
can.
liquid, and vapour in the aerosol can head
This is a very critical operation and the crimping
space. The volume of liquid in the can will
machinery has to be carefully set up to ensure
increase. If a compressed gas is used, it will
Fit valve that the can / valve seal does not leak. Add propellant usually only be in the head space, above the
liquid in the can, and there will be little or no
increase in liquid volume.
How are aerosol filled 28

1 · The propellant is forced (about 50 BAR) through the valve into the aerosol can.
2 · The propellant enters through the stem / housing / dip tube and between the stem / dome mounting cup / inner gasket / housing.

1. 2.
 How are aerosol filled 29

Crimping quotes

The quotes below are usually suggested for Coster valves and tin plate or aluminium cans with neck dimension according to Fea standard.
The quotes below are only indicative. They must be confirmed or slightly modified only after sealing tests with significant number of samples.

CAN MATERIAL
MOUNTING CUP
TINPLATE ALUMINIUM
MATERIAL
HEIGHT DIAMETER HEIGHT DIAMETER

TIN PLATE 4.90 ± 0.05 27.10 ± 0.10 4.95 ± 0.05 27.10 ± 0.10

ALUMINIUN NO NO 5.15 ± 0.05 26.90 ± 0.05

LAMINATED TIPLATE 4.35 ± 0.10 27.10 ± 0.10 NO NO

 30

05 Coster Pharma
Coster in a nutshell 31

 2019 Turnover: 210 Million Euro

 Headcount: 900 Employees
 1963 - 2020: 57th Anniversary
 Manufacturing sites: 15 Globally
• Italy: 8 (Trento / Milan)
• Europe: 3 (NL / Spain / UK)
• Asia: 2 (India / Malaysia)
• USA: 1 (Chicago)
• South America: 1 (Argentina)
 Customers: + 600
Coster in a nutshell 32

COSTER 1
CALCERANICA – TRENTO
Technical and R&D
Headquarters

COSTER 2
CALCERANICA – TRENTO
Clean Room Manufacturing
Pharma division 33

Key features and assets Product suite

 Sole company supplying packaging  MDI valves and

components and filling machines for actuators
MDI, nasal, oral and topical products  Spray pumps and
 Dedicated Clean Rooms class ISO 7 and dispensers
ISO 8  BOVs (one inch and
 ISO 15378 certified 20 mm)
 DMF Type III for MDI valves  Filling machines for DEDICATED CLEAN ROOMS
 State-of-the-art manufacturing and MDIs, nasal and oral
sprays, topical COMPLETE RANGE OF SOLUTIONS
assembly equipment
products HIGH PRODUCTION STANDARDS
 Formulation and reformulation services
on selected products
VALVES, BOV, PUMPS, ACTUATORS
 Coster assets and capabilities 34

Clean Room Aerosol Technology Manufacturing

In-house analytical & Formulation Services Documentation
manufacturing courses & training excellence
compatibility tests Reformulation Experts
GMP Certifications in on the spot or at Technological know-
Dedicated Labs Services Regulatory Support
place customer site how & expertise

At the forefront of Europe & the Aerosol experts since Dedicated Lab Dedicated Technical
Dedicated Team
technology Americas 1963 Managers Resources
Pharma packaging solutions 35

Coster provides packaging solutions for pharmaceutical applications:

NASAL applications INHALATION applications

INHALATION applications
TOPICAL applications ORAL applications
Product portfolio 36

New products and strategic partners

Pharma AirNext Neptune Mini inhaler Upgrading of KPM & 32D valves Metering BOVs

RPC Presspart Plastiape/RPC Ursatec/Aeropump

Dose Indicator Ear & oral actuators Oral actuator Preservative-free pumps
Products for nasal applications 37
Pulmonary applications 38
Products for topical applications 39
Products for oral applications 40
Machinery division 41

 Semi-automatic machines
 Fully-automatic machines
 For filling MDIs, nasal and oral spray, topical products
 Local technical support
Aerosol production worldwide 42

PRODUCTION WORLDWIDE IS ESTIMATED AT MORE THAN:

a) 1,5 billion units

b) 5 billion units

c) 10 billion units

d) 15 billion units
Aerosol production worldwide 43

PRODUCTION WORLDWIDE IS ESTIMATED AT MORE THAN:

a) 1,5 billion units

b) 5 billion units

c) 10 billion units

d) 15 billion units, of which 7% (1,05 billion) is

equivalent to the production of pharmaceutical
aerosols.
www.coster.com

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