Aerosol Can Selection Guide: A Comparison of Aluminum Cans ,Tin Cans and Plastic Bottles
As a manufacturer of aerosol filling machines, we deal with various types of aerosol cans on a daily basis. Aluminum cans, tin cans (tinplate cans), and plastic bottles—while they may seem like mere differences in packaging containers, they actually determine your product’s filling process, shelf stability, and even market positioning.
Different can types require different filling line configurations, sealing parameters, and safety standards. The purpose of this article is to help aerosol manufacturers understand the core differences between these three mainstream aerosol can types from the outset, enabling them to make more informed choices for their products.
1. Aluminum Cans
(1) Manufacturing Characteristics
Aluminum cans are manufactured using a seamless extrusion process, resulting in a can body without weld seams. The inner walls are typically coated with protective layers such as epoxy-phenolic or polyimide resins. Their pressure resistance generally ranges from 12 to 15 bar, which far exceeds the actual requirements of most aerosol products. Aluminum cans have high recycling value and can be recycled indefinitely without degradation, making them an excellent choice for sustainability.
(2) Advantages
lLightweight: Approximately 30% lighter than steel cans for the same capacity, reducing transportation costs.
lHigh-quality printing: Supports 360° seamless offset printing or heat transfer printing, ideal for creating a premium brand image.
lExcellent corrosion resistance: Aluminum has strong inherent oxidation resistance; combined with an internal coating, it can withstand most corrosive formulations.
(3) Typical Applications
Hairspray, perfume, sunscreen spray, shaving foam, medicinal inhalers, premium deodorants.
(4) Filling Considerations (Equipment Perspective)
lAluminum cans have relatively thin walls (approx. 0.15–0.25 mm). During filling, the rate of pressure change must be controlled to prevent bottom bulging or body deformation caused by pressure shocks.
lBefore filling, it is recommended to purge the can with oil-free compressed air or ionized air to remove any residual aluminum particles and prevent valve blockage.
lSealing must be performed using a specialized sealing head that matches the curvature of the aluminum can. Sealing pressure should be kept within a low range (typically ≤200 kgf) to prevent damage to the can caused by excessive pressure.
lIf liquefied propellants (LPG, DME, etc.) are used, the filling line must be equipped with an explosion-proof system.
2.Tin Cans (Tinplate Cans)
(1) Manufacturing Characteristics
Tin cans are primarily constructed from three panels (can body, top, and bottom), with the can body formed by welding tinplate sheets. The inner walls are coated with anti-corrosion coatings such as epoxy-phenolic resin or PVC organic sol. The typical pressure resistance is approximately 10–12 bar. The weld seams of tin cans require special attention, as corrosion is likely to occur if the coating coverage is inadequate.
(2) Advantages
lLower cost: Raw material and processing costs are relatively lower than those of aluminum cans, making them suitable for high-volume fast-moving consumer goods.
lMature supply chain: Standard-sized steel cans are readily available, and molds are highly versatile.
lHigh mechanical strength: The can body has good rigidity and is impact-resistant, making it suitable for high-speed conveying and filling.
(3) Typical Applications
Pesticides, automotive care products (carburetor cleaners, tire foam), industrial release agents, spray paint, rust inhibitors.
(4) Filling Considerations (Equipment Perspective)
lThe weld seam is the weakest point of a steel can. Weld seam detection sensors should be installed on the filling line to reject cans with abnormal weld seams or damaged coatings.
lSteel cans have high rigidity, and sealing pressure is typically 250–350 kgf. The pressure must be uniform and stable to avoid stress concentration at the weld seam.
lDue to the risk of micro-pores in the weld seam, it is strongly recommended to perform a water bath leak test after filling to ensure airtightness.
lSteel cans are compatible with all types of propellants (LPG, DME, compressed gas); however, an explosion-proof system must be installed when using flammable propellants.
3.Plastic Bottles
(1) Process Characteristics
Plastic aerosol cans are primarily manufactured using the injection-stretch-blow molding (ISBM) process, with materials typically consisting of PET, PETG, or multilayer cans featuring an EVOH barrier layer. Under technically mature conditions, PET aerosol cans can use LPG as a propellant, with isobutane exhibiting the best compatibility with PET. Compatibility between different propellants and PET varies: Due to its high solubility, DME has relatively poor compatibility with PET, requiring thorough aging tests prior to use. According to international fire safety standards such as NFPA 30B, the capacity of plastic aerosol cans using liquid propellants is typically limited to 118 ml (4 oz) or less, while EU regulations restrict it to 220 ml or less. The operating pressure of plastic containers generally does not exceed 9–10 bar, depending on the container design and material.
(2) Advantages
lVisible contents: The transparent material allows consumers to visually check the remaining quantity, enhancing the user experience.
lLightweight and impact-resistant: Lighter and more resistant to knocks than metal cans.
l Good safety characteristics: Even if internal pressure becomes too high, the container typically cracks or tears, producing no sharp fragments.
lEco-friendly: PET is recyclable, and its production and transportation involve lower carbon emissions.
lHigh design flexibility: Supports a wide range of bottle shapes, sizes, and surface finishes, making it suitable for high-end applications such as cosmetics.
lPET bottles do not require internal coating treatment, unlike aluminum or tin cans.
(3) Typical Applications
Air fresheners, foaming hand wash/body wash, food-grade aerosols (e.g., whipped cream), cosmetics (deodorants, sunscreen sprays), low-toxicity horticultural sprays, and automotive care products.
(4) Filling Considerations (Equipment Perspective)
lPropellant compatibility must be verified in advance: When using liquefied propellants (LPG, DME), the long-term compatibility between the bottle material and the propellant must be confirmed. PET has good compatibility with isobutane but poor compatibility with DME; it is recommended to conduct accelerated aging tests for at least 3 months prior to mass production.
lAdhere to capacity safety limits: For plastic bottles using flammable liquefied propellants, the single-bottle capacity must be strictly controlled in accordance with international fire safety regulations (generally not exceeding 118 ml); exceeding this limit requires compliance with additional safety tests and protective measures.
lNon-standard bottle necks and ovality control: Due to the prevalence of non-standard designs in plastic bottle necks, Filling Equipment must be equipped with quick-change seal sets and adaptive bottle neck centering devices. It is also recommended to install in-line ovality detection to reject bottles with out-of-tolerance roundness, thereby preventing gas leakage after capping.
lExplosion-proof configuration: When using flammable liquefied propellants, the filling line must be equipped with an explosion-proof system; explosion-proof requirements are less stringent when using compressed non-flammable gases.
4.Summary
Aluminum cans, steel cans, and plastic bottles each have their own suitable product applications and filling process requirements; there is no absolute distinction between which is better or worse.
• Aluminum cans are suitable for mid- to high-end products with high requirements for weight, appearance, and corrosion resistance. The filling process requires careful attention to pressure control and the use of specialized sealing dies.
• Tin cans excel in cost-effectiveness and mechanical strength, making them a proven choice for high-volume fast-moving consumer goods. Key focus areas include weld quality and leak testing.
• Plastic bottles offer unique advantages in transparency, lightweight design, and safety. They can accommodate liquefied propellants such as LPG, but compatibility testing must be conducted based on the bottle material, and capacity safety limits must be strictly adhered to.
As a filling machine manufacturer, our value lies in providing tailored filling solutions for every container type—ranging from semi-automatic to high-speed fully automatic lines, and covering the entire process from product filling to propellant charging, leak testing, and capping. If you are selecting a can type for your aerosol product or planning a filling line, we welcome your inquiries.
The content of this article is based on general technical knowledge and publicly available standards in the aerosol filling industry. Please refer to the technical specifications for specific equipment parameters.