Plastic Aerosols

When Safety meets Style

Dr. Hartmut Schiemann P&G Service GmbH

XXVII. Aerosol Congress in Rome

Plastic Aerosols A History

1951-1955: First non-metallic aerosols made of uncoated glass

=> establishment of limits across the world
(4 fl.oz. =118 ml in US, 100 ml in Japan, 150 ml in Europe etc.)
however, many countries did not differentiate
=> same criteria for metal and plastic
1956: 19 ml (bakelite)
1958-1980: different types of opaque plastics in small sizes
1980-1990: transparent and opacified PET cans developed
1997: Cans made of PEN and PET/PEN developed
Regulations worldwide recognize:
PET, PEN, Nylon, Ethylene Vinyl Alcohol (EVOH) or their blends
XXVII. Aerosol Congress in Rome

Plastic Aerosol Facts

European Aerosol
Production 2004-2007
z Can material shares in %
z Plastic is almost
exclusively PET
(glass is negligible)
z Trend: increasing
production of deodorants,
which require aluminium
cans with specific coating
(epoxy)
z Increase in plastic is not
really significant

70
60
50
40
30
20
10
0

62,7

54,19
45,45

2004

37,1

2007

0,2
Tin Plate

XXVII. Aerosol Congress in Rome

Aluminum

0,36

Plastic (&Glass)

Plastic Cans => Possibilities?

Transparent ?

XXVII. Aerosol Congress in Rome

Plastic Cans => Possibilities?

Stylish shapes ?

Learn from beverages?

XXVII. Aerosol Congress in Rome

Plastic Aerosol Myths

Plastic is cheaper than metal

Plastic can be shaped more attractively
Plastic has a better corrosion resistance
than metal

XXVII. Aerosol Congress in Rome

Plastic Aerosol Myths

Plastic is cheaper than metal

Plastic can be much more expensive than metal
Dont compare beverage bottles!

Plastic can be shaped more attractively

Today: Difficulties to shape plastic cans more attractively
=> cost!!!

Plastic has a better corrosion resistance

than metal
Plastic has a better corrosion resistance than metal, but
permeation is a show stopper in many cases.
Be aware of UV rays
XXVII. Aerosol Congress in Rome

Safety for all Aerosol Packs

All aerosol packs shall withstand a temperature up to

50C
z No leak shall occur
z The container shall not burst
Increase in temperature causes an increase in pressure
Mechanical resistance up to at least 50C
There must be no possibility that the mechanical
resistance of the aerosol dispenser can be impaired by
the action of the substances contained in it, even during
prolonged storage.
Long term chemical resistance
XXVII. Aerosol Congress in Rome

Legal state of the art in Europe

ADD 75/324/EEC and revision in 2008:

Requirements for Plastic are the same as for Glass
z Plastic aerosol dispensers which may splinter on bursting
shall be treated in the same way as unprotected glass
aerosol dispensers.
z Plastic aerosol dispensers which cannot splinter on bursting
shall be treated in the same way as glass aerosol dispensers
with a protective coating.
This is a consequence of history:
z First aerosols had been made of metal and glass
z Plastic had been considered only later; many applications
failed in market
XXVII. Aerosol Congress in Rome

Legal state of the art globally

British Standard BS 5597:1991

z Several exemptions in US and Canada based on BS
5597:1991
z Key message:
Plastic aerosol cans fulfilling the same requirements (and
some more) can have the same maximum brimful volume as
metal cans (1000 ml) and can be filled the same way as
metal cans (maximum pressures of 13.5 bar at 55C,
adapted in US 160 psig at 130F and Canada 1105 kPa
=11.03 bar at 55C)
z Therefore basic reference for all recent amendments of
standards in US, Canada and on the way in Europe

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Legal state of the art globally

ADR (European Agreement concerning the International Carriage of
Dangerous Goods by Road)
z Plastic aerosol cans can be made of any plastic/synthetic
material
z Brimful volume up to 500 ml
z Max. pressure 1.32 MPa at 50C
z Other references
International Maritime Dangerous Goods Code (IMDG Code)
Regulations concerning the International Carriage of
Dangerous Goods by Rail (RID)
ICAO (International Civil Aviation Organization)
z Plastic is only PET, PEN, Nylon and/or EVOR (combinations)
z More detailed and specific requirements, including ageing
aspects and drop test
z Brimful volume up to 500 ml, but only for non-flammable, nontoxic gas and contents; otherwise 120 ml only
z Max. pressure 974 kPa at 55C
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Important criteria on Plastic Cans (1)

Drop test
z has been even expanded to respect approaches of other
regulations (e.g. different temperatures from ICAO)
z Area for drop test (concrete floor) like Standard ISO 2248;
z Same height of 1.8 m for single containers/aerosol packs and
transport packs
All drop test shall be at required temperature (different to ISO
16104, where 5 minutes transfer time are permitted from
conditioning environment to test area)
z Temperature at 18C after 24 hours conditioning
z 55C after 6 hours conditioning
z 40C additionally for aerosol packs after 3 months conditioning
XXVII. Aerosol Congress in Rome

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Important criteria on Plastic Cans (2)

Waterbath testing is difficult for plastic cans, especially drying with

hot air afterwards
Alternative test methods to hot water bath apply and are
recommended
Additional hot air test:
5 hours at test temperature that will be fixed at 7C below the
container materials glass transition temperature (Tg). However
the test temperature will not be lower than 65C and not higher
than 75C
This test shall also ensure that no material is selected that does
not fulfill what metal cans normally provide by their natural
temperature resistance.
This test is not included in legal proposals (to maintain alignment
of legal requirements with those for metal cans)

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Requirements for Aerosol Packs

Metal

Uncoated glass/
splintering plastic

Coated glass/ non

splintering plastic

Plastic - Proposal

Maximum Capacity
(brimful)

1000 ml

150 ml

220 ml

1000 ml

Filling pressure at 50C

depending on
propellant (liqufied,
solved or compressed
gas)

<= 12 bar for liquefied

propellant
<= 13.2 bar for
compressed, nonflammable gas

Complex for
liqufied
propellants
<= 8 bar for
dissolved gas

Complex for
liqufied propellants
<= 8 bar for
dissolved gas
<= 9 bar for
compressed gas

<= 12 bar for liquefied

propellant
<= 15 bar for
compressed, nonflammable gas
(for metal and plastic)

Test pressure

Minimum 10 bar
50% higher than internal
pressure at 50C

12 bar

12 bar for dissolved

or compressed gas
10 bar for liquefied
propellant

Minimum 10 bar
50% higher than internal
pressure at 50C

Burst pressure

20% higher than test

pressure

No requirement

No requirement

20% higher than test

pressure

Burst behaviour

Not specified

splintering

Not splintering

Not splintering

Final inspection

Hot water bath or

alternative
=> No leak, no distortion

Hot water bath or

alternative
=> No leak, no
distortion

Hot water bath or

alternative
=> No leak, no
distortion

Hot water bath or

alternative
=> no leak, slight
symmetrical distortion
possible

Drop test

No requirement

No requirement

At 20C from 1.8 m

At -18C, 40C and 55C

from 1.8m

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Summary
Plastic Aerosol Cans are in market today
Current legislation allows worldwide plastic cans up to
500 ml brimful volume (except Europe and parts of Asia)
European Commission asked for harmonization with
global regulations in 2005
Recently Plastic Cans up to 1000 ml brimful volume
became standard in North America, based on British
Standard
FEA supports Plastic Cans up to 1000 ml and increased
pressure up to 15 bar (13.2 bar at least) => no different
requirements compared to metal cans
Target to amend European Directive is 2011
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Questions ?

Happy to answer questions, if needed:

Dr. Hartmut Schiemann
Procter & Gamble Service GmbH
Berliner Allee 65
D-64274 Darmstadt
Germany
E-mail: schiemann.h@pg.com
Tel.: +49 170 893 4190

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