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.

Our aerosol filling machines handle all common propellant types: Liquefied Petroleum Gas (LPG/butane/propane blends) — most common for paints, hairsprays and household products; Dimethyl Ether (DME) — used in personal care products; Carbon Dioxide (CO₂) — food-grade and non-flammable applications; Nitrous Oxide (N₂O) — cosmetic and food products; Nitrogen (N₂) — non-flammable technical applications. Flammable propellant systems include ATEX-rated components throughout.

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 certification is required when filling flammable propellants (LPG, DME, propane) or flammable product concentrates. All components in the filling zone — motors, controls, sensors, pumps — must be rated for the appropriate Zone (Zone 1 or Zone 2 depending on facility classification). Our standard aerosol lines include ATEX Zone 2 rated components as standard when handling flammable propellants. Zone 1 configurations are available for higher-risk applications.