Aerosol Filling Machines

An aerosol filling machine is a specialized system that fills pressurized aerosol cans in two stages: (1) Product fill — liquid concentrate is filled under atmospheric pressure into the open can; (2) Propellant charge — the can is sealed with a valve, then pressurized propellant (LPG, CO₂, N₂O or DME) is injected under the valve cup or through the valve. The result is a self-dispensing pressurized product. Our machines handle single-stage through fully integrated multi-stage lines.

Aerosol filling RFQs can be reviewed for common propellant types such as LPG blends, DME, CO₂, N₂O, nitrogen and compressed air. Flammable propellant systems require hazardous-area review based on the product formulation, facility classification, electrical protection concept and destination-market documentation needs.

Under-the-cup (UTC) gassing injects propellant between the valve cup and the can lid before crimping — the most common method for LPG-filled products. Through-the-valve (TTV) gassing injects propellant through the already-crimped valve using a high-pressure adapter — used for CO₂ and N₂O filling. UTC achieves faster fill rates and is standard for most aerosol products. Our lines support both methods and can be configured for your specific propellant and product combination.

Our aerosol filling machines support standard aerosol can diameters of 45mm, 52mm, 57mm, 65mm and 70mm, in heights from 75mm to 300mm, covering standard volumes from 50ml to 1,000ml. The machines use adjustable guides and tooling for rapid format changeover — typically 20–30 minutes between can sizes. Custom tooling for non-standard can dimensions is available.

ATEX or equivalent hazardous-area documentation may be required when filling flammable propellants or flammable product concentrates. Motors, controls, sensors, pumps and filling-zone layout are reviewed against the facility classification, product SDS and destination-market requirements before the final configuration is confirmed.