The Process of Aerosol Manufacturing: A Comprehensive Overview

The production commences with the manufacturing of the aerosol container. Cans vary in design complexity and material. One-piece cans, formed by pressing a single sheet of metal, are highly durable with a pressure resistance of up to 45 bar. Two-piece cans involve joining the sidewall to the bottom and lid. Three-piece cans have the most intricate production process. It starts with decorating the metal sheet through varnishing and painting. The body is then created by rolling and welding the sheet's edge. The bottom and lid are separately produced by pressing cut metal pieces and finally assembled. Notably, can production occurs in specialized factories independent of the subsequent filling processes.

dIn the filling factory, the second stage involves placing the empty cans onto a feeding table and then transferring them to a pelletizing machine. This machine is crucial for products like paints or technical substances. Its function is to insert a specific number of balls into the can to facilitate product mixing before use. Solmatic's bead blasters, for instance, can insert 1 to 4 balls at a rate of 60 cycles per minute.

The core step is filling the cans with the product followed by installing and crimping the valves. Filling and crimping machines are the linchpins of the production line. Liquid products are poured into the cans using a filling module that can operate in different systems such as rotary, indexing, or in-line. The filling speed depends on factors like container size, product volume, composition (alcohol-based products fill faster than oil-based ones), and physical-chemical properties (density, viscosity, foaming tendency). After filling, appropriate sorters select and insert valves into the cans, and clamping devices ensure a tight seal.

Subsequently, the cans enter the gasification module. This stage is vital for safe gas filling. The automatic gas filling module, usually located in a specific area like the Gas House, is designed to operate in potentially explosive environments. Cans are filled with a predetermined amount of gas at designated workstations, with the help of interchangeable sets for different can diameters to ensure proper alignment.

Testing the tightness of aerosols is a critical quality control measure, especially when dealing with flammable gases. Various machines like automatic test tanks, leak detectors, or laboratory test tanks (for small-scale production) can be employed. Simultaneously, the cans are weighed on an automatic scale to eliminate those with incorrect fill amounts of substance or gas. Only cans passing both tests proceed to the next stage.

The cans then move to jigs. These devices automate the process of placing heads, caps, or closures on the cans. This automation not only reduces the workload on employees but also enhances the consistency and efficiency of the process, leading to cost savings and increased productivity.

The final stage involves packaging the aerosol cans. In less automated plants, packing is mostly manual at the receiving table. In contrast, highly automated factories use semi-automatic or automatic packing systems. Once packed, the cans are ready for transportation, which is a separate and complex logistical process.

III. The Significance of Technological Lines in Aerosol Production