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The ins-and-outs of aerosol innovations

What you see is not all of what you get

The first large-scale use of aerosols was insect repellant used by U.S. soldiers fighting in the Pacific during WWII. These decades later, the core concept─a container, pressurized by a propellant, dispensing contents through a valve assembly─remains the same. However, a variety of innovations continue to be wrapped around that core. One way to discuss those innovations is to proceed from interior components to exterior components, but staying mindful of the systems interrelationships among components (for related reading, see: All about aerosols, Packaging Insights Newsletter, 04/07/16)
What qualifies as innovations? Beyond “newness,” there are subjective and comparative factors. That said, innovations should enhance benefits to the consumer, resulting in increased sales and profits.

Propellants

Ever since chlorofluorocarbons (CFCs) were banned in the 1980’s, the aerosol industry has had to use propellants that pass environmental muster. The list continues to grow beyond the familiar and now includes entries named alphanumerically and others sold under registered brand names. Choosing a single propellant from among many is daunting enough, made more so by the often-forced necessity of blending them. In addition to environmental concerns, product formulators can give structure to their decision-making with the right set of criteria.

Cost is always a criterion; however, it should be evaluated in terms of the ratio of propellant to product. The ratio not only affects the cost of propellant but also the size of the aerosol container (and thereby, its cost). Another criterion is the pressure that a propellant can be placed under and consequently exert during dispensing. The objective should be even flow and full evacuation of contents. Yet another criterion is compatibility/stability between propellant and product. For example, whether the product is water-based or solvent-based affects its ability to form an emulsion with a given propellant. One more criterion is toxicity, the existence of which eliminates a propellant from food and pharma use. And don’t forget about flammability; all other considerations being equal, non-flammability is preferred.

The merits of compressed air as a propellant are being touted by at least several suppliers, an interesting claim being the ability to dispense regardless of the position (i.e. upright, sideways, or upside-down) of the container. Whereas the environmental safety of compressed air is not an issue, its applicability should be determined using the aforementioned criteria.

Actuators and valves

Some marketers of aerosols are differentiating on the basis of the characteristics of the spray. An example is a currently-running television commercial for a major brand, emphasizing the wider angle of the spray; and, although that’s a benefit with certain products, a moment’s reflection will suggest products that benefit from a narrow spray. The point being made is that technology will continue to be applied to these aspects.

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