3. AEROSOL TECHNOLOGY
Propellants – Numbering System:
The Various Propellants are Usually Distinguished by a
Number
Rule 1: The First Digit on the Right Signifies the
Number of Fluorine (Fl) Atoms in the Compound.
Rule 2: The Second Digit From the Right is
Numerically One More Than Number of Hydrogen (H)
Atoms in the Compound.
Rule 3: The Third Digit From the Right is Numerically
One Less Than the Number of Carbon (C) Atoms in
the Compound. When the Digit Is Zero, It is Omitted
From the Number.
4. AEROSOL TECHNOLOGY
Propellants – Numbering System:
Rule 4: The number of chlorine (Cl) atoms
in the compound is found by subtracting
the sum of the fluorine and hydrogen
atoms form of the atoms that can be
connected to carbon. When only one
carbon atom is involved, the total number
of attached atoms is four. When two
carbon atoms are present, the total
number of attached atom is six.
12. AEROSOL TECHNOLOGY
Propellants – Dymel®
Dymel® A / Water Combination
Used in high water system
Can be used with Hydrocarbon
propellants
13. AEROSOL TECHNOLOGY
Mac Bhuta
Propellants – Solubility
Propellant Prop. In Water Water in Prop. KB Value
Dymel® A 35% 6% 60
Dymel® 152a 0.28% 0.17% 20
Propane 0.0079% 0.168% 15
n-Butane 0.008% 0.0075% 20
iso-Butane 0.008% 0.0088% 18
iso-Pentane 0.0084% 0.0063% 21
14. AEROSOL TECHNOLOGY
Mac Bhuta
Propellants – Solubility
Improving Solubility in Aqueous
Systems:
Dymel® A enhances solubility
Forms hydrogen bonds with
water molecules
15. AEROSOL TECHNOLOGY
Propellants – Dymel®
Dymel® or Klea® 134a (CH2FCF3)
No VOC, Non Flammable
Properties close to Freon® 12
But Global Warming Potential is
1300 CO2 = 1
-Almost ten times more than Dymel®
152a
16. AEROSOL TECHNOLOGY
AZE0TROPE
An Azeotropic is A Mixture is Defined as One Compound
Of Two Or More Solvents Which Has A Maximum Vapor
Pressure For That System (And A Minimum Boiling
Temperature) Which Can Distill With The Composition
unchanged.
It Is Where The Liquid And Vapor Compositions Are The
Same. When Azeotrope Propellant Sprayed Will Not
Change in Composition Since The Composition In The Head
Space Is The Same As That In The Liquid.
18. AEROSOL TECHNOLOGY
TOXICOLOGY OF DYMEL® PROPELLANTS
A. LOW ODOR OF INHALATION TOXICITY IN
EXTENSIVE ANIMAL TESTING.
B. NOT STRONG CARDIAC SENSITIZERS.
C. ALL STUDIES TO DATE SUPPORT AN 8 HOUR TWA
OCCUPATIONAL EXPOSURE LIMIT OF 1000ppm (HIGHEST
ALLOWED FOR ORGANIC COMPOUNDS)
D. NO HAZARD TO MAN RELATIVE TO SYSTEMATIC
TOXICITY, CARCINOGENICITY, MUTAGENICITY, OR
TETRATOGENICITY WHEN USED WITHIN OCCUPATIONAL
EXPOSURE LIMIT.
19. AEROSOL TECHNOLOGY
DYMEL® 134a NON FLAMMABLE BLENDS
Flammable MAXIMUM
COMPONENT CONCENTRATION
WEIGHT%
HFC-152a 12.0
DME 3.5
ISOBUTANE 3.0
20. AEROSOL TECHNOLOGY
ENVIRONMENTAL PROPERTIES OF DYMEL®
PROPELLNATS
DME HFC-152a HFC-134a
OZONE DEPLETION 0 0 0
POTENTIAL (ODP)
VOLATILE ORGANIC YES NO NO
COMPOUND (VOC –USA)
ATMOSPHERIC LIFETIME <0.1 1.5 14
YEARS
GLOBAL WARMING NIGLIGIBLE 140 1300
POTENTIAL (100 YR.
INTEGRATED TIME HORIZON )
21. ATMOSPHERIC PROPERTIES OF COMMON PROPELLNATS
Compound At. LT(Years) ODP GWP(100 yr) VOC
CFC-11 50 1.00 4000 N
CFC-12 102 1.00 8500 N
HCFC-22 13.3 0.05 1700 N
HCFC-141b 9.4 0.10 630 N
HCFC-142b 19.5 0.06 2000 N
HFC-152a 1.5 0.00 140 N
HFC-134a 14 0.00 1300 N
DME 6-7days 0.00 3 to 11 y
PROPANE 15 days 0.00 3 to 11 Y
Butane 6-7 days 0.00 3 to 11 y
Isobutane 6-7days 0.00 3 to 11 y
22. AEROSOL TECHNOLOGY
Global Warming:
Global temperatures are dangerously close to the
highest ever estimated to have occurred in the past
million years. Earth has been warming rapidly, nearly
0.36º F (0.2º C) in the last 30 years.
If global temperatures go up to 1.8º F ( 1º C) , It
would be equal to the maximum temperature of the
past million years
This evidence implies that that we are getting close
to dangerous levels of human made (anthropogenic)
POLLUTION.
23. AEROSOL TECHNOLOGY
Human Influences on Global Warming:
Humans might be magnifying warming by
adding to the greenhouse gases naturally
present in the atmosphere. Fuel use is the
chief cause of rising carbon dioxide levels. On
the other hand, humans create temporary,
localized cooling effects through AEROSOLS,
such as smoke and sulfates from industry,
which reflect sunlight away from earth
47. AEROSOL TECHNOLOGY
Flammability:
Aerosol Level 2:
Flammable propellants with an
alcohol-based concentrate
(25% or more water soluble
alcohol/s by weight) – (Water
soluble flammable concentrate).
Mac Bhuta
49. AEROSOL TECHNOLOGY
Flammability:
1>: If a product contains more than 50%
flammable propellants, the classification is
automatically increased by one level.
2>: If a product contains non-flammable
propellant(CO2,N2 etc.)is not considered a
“flammable gas” and is not subject to this
classifications system.
51. AEROSOL TECHNOLOGY
Aerosol Storage in Warehouses
Level 1 Aerosol Products Considered Equivalent Class
III Commodities-NFPA 13. Std. Sprinkler System
Level 2 & 3 According To Section 6.3.NFPA 13.
Level 2 & 3 Not Permitted In Basement Area
Aerosols Must Not Be Stored In The Production
Buildings Of A Plant.
Aerosols must be isolated from the other buildings 10
meters or greater.
52. AEROSOL TECHNOLOGY
Aerosol Waste
1. The Storage of WASTE of
Aerosols must be located outside of
the building. If possible to isolate
from the building by a distance of 20
meters.
54. AEROSOL TECHNOLOGY
Propellants – Compressed Gas
Advantages:
Non-flammable
Inexpensive
Environmentally Acceptable
Odorless and Colorless
Low in Toxicity
Changes in temperature causes only minor changes
in pressure
55. AEROSOL TECHNOLOGY
Propellants – Compressed Gas
Disadvantages:
Spray characteristics change during is
change
Pressure decreases during use
Flow rate decreases
Spray becomes increasingly coarser
Misuse
57. AEROSOL TECHNOLOGY
Propellants – Formulation
Vacuum purge prior to Crimping
Selection of right Valve and
Actuator
Effect of Temperature
Effect of Vapor Tap
Variation in Actuator
58. AEROSOL TECHNOLOGY
Propellants – Formulation
The following variables affect spray
characteristics:
Variation in Propellant and
Concentration Ratios
Variation in Propellant and its blend
Variation in Valve and Actuator, or
both
59. AEROSOL TECHNOLOGY
Propellants – Formulation
The Formulator MUST consider the following
Corrosion study – Aerosol can / Valve
Cooling effect of Aerosol – Deodorants
/Antiperspirants
Solubility and Cloud point of the product
Freeze/Thaw – Emulsion products
Foam quality – Wetness/Density/Stiffness
71. AEROSOL TECHNOLOGY
CALCULATION :-Aerosol Density
Aerosol Density is worked out by following way:--
Formulation: 55% Concentration…………………….55.0 g
45% propellant………………………….45.0 g
Specific Gravity of Concentrate…………………..0.80 g/cc
Specific Gravity of Propellant………………………...0.91 g/cc
Can Size and its Overflow Capacity
45 X 150 mm ……………… 209 cc
Now, Concentrate divided by Sp. Gr. of Concentrate
55 g divided by 0.80 g/cc = 68.75 cc
Propellant divided by Sp. Gr. Of Propellant
45 g divided by 0.91 g/cc = 49.45 cc
Add 68.75 cc & 49.45 cc = 118.20 cc
100 g divided by 118.20 cc = 0.8460 g/cc this is Aerosol Density
72. AEROSOL TECHNOLOGY
The DOT Regulations Specify
That An Aerosol Package Must
Not Become Liquid Full @ 130º F
To Determine The Volume Of
Any Given Weight Of A Product
@ 130º F, It Is Necessary To
Know The Aerosol Density.
73. AEROSOL TECHNOLOGY
CALCULATION :- Head Space
Physical Requirements:
An aerosol container has a safe fill if there is a minimum
7.5 % Head Space within container when the contents are
heated to 130°F(54.4°C), except a 4.5 % head space is
considered safe at 130°F(54.4°C) provided:
The container has concave base which becomes convex
at pressure significantly below the burst pressure or has
came that can be everted at the chime at pressure
significantly below the burst pressure.
74. AEROSOL TECHNOLOGY
CALCULATION :- Head Space
Head Space is worked out by following way:--
Can Size & its Overflow Capacity
45 x 150 mm ……………………………209 cc
Aerosol Density …………………………… 0.8460 g/cc
209 minus 5 cc(Valve displacement) = 204 cc
204 cc x 80% full x Aerosol Density g/cc
204 cc x 0.80 x 0.8460 g/cc = 138 g
138 g divided by 28.35 g = 4.9 oz
(28.35 g = 1.0 oz)
75. AEROSOL TECHNOLOGY
Head Space
Can Size:53X240, Fill
Weight:309 G, 34.2 %
Head Space @ 70° F
Can Size:53X240, Fill
Weight:309 G, 33.7 %
Head Space @ 130° F
76. AEROSOL TECHNOLOGY
Head Space
Can Size:53X240, Fill
Weight:401.2 G, 34.2 %
Head Space @ 70° F
Can Size:53X240, Fill
Weight:401.2 G, 11.2 %
Head Space @ 130° F
77. AEROSOL TECHNOLOGY
CALCULATION :- AEROSOL DENSITY
WORK STUDY
SUBJECT: FIND OUT CALCULATED AEROSOL DENSITY
AEROSOL FORMULA:
60.0% CONCENTRATE – LIQUID SP.GR. 0.768 g/cc
10.0% PROPELLANT A – LIQUID DENSITY – 0.578 g/cc
30.0% PROPELLANT B – LIQUID DENSITY – 0.910 g/cc
78. AEROSOL TECHNOLOGY
CALCULATION :- AEROSOL DENSITY
WORK STUDY
SUBJECT: FIND OUT CALCULATED AEROSOL DENSITY
AND NET WEIGHT & NET VOLUME
AEROSOL FORMULA:
55.0% CONCENTRATE – LIQUID SP.GR. 0.823 g/cc
29.0% PROPELLANT A – LIQUID DENSITY – 0.910 g/cc
16.0% PROPELLANT B – LIQUID DENSITY – 0.660 g/cc
79. AEROSOL TECHNOLOGY
CALCULATION :- AEROSOL DENSITY
WORK STUDY
SUBJECT: FIND OUT CALCULATED AEROSOL DENSITY
AND NET WEIGHT & NET VOLUME & CAN SIZE
AEROSOL FORMULA:
60.0% CONCENTRATE – LIQUID SP.GR. 0.780 g/cc
40.0% PROPELLANT A – LIQUID DENSITY – 0.910 g/cc
80. AEROSOL TECHNOLOGY
CALCULATION :- Vapor Pressure of Blend
The blend is 152a & isobutane
V. P @ 70º F
psig psia mol. Wt
Dymel® 152a 62.5 77.2 66.1
Isobutane 31.0 45.7 58.1
assume 100 G of solution; 30% 152a = 30 G; 70% isobutane = 70 G
30 divided by 66.1 = 0.4593 moles of 152a
70 divided by 58.1 = 1.2048 moles of isobutane
total moles of mixture: 1.6587
now, 0.4593 divided by 1.6587 = 0.274 mole fraction
1.2048 divided by 1.6578 = 0.726 mole fraction
partial pressure of 152a: 0.274 x 77.2 = 21.15 psia
Partial pressure of isobutane 0.726 x 45.7 = 33.18 psia
therefore, 21.15 + 33.18 = 54.68 psia
minus 14.70 psig = 39.98 psig
81. AEROSOL TECHNOLOGY
80% VOC Hair Spray Formulation( Wt%)
Ingredients Value Brand Performance
Brand
Salon
Brand
Resin 5 5 5
Ethanol 50 57.5 75
Hydrocarbon 15 15 5
Dymel® A 15 7.5
Dymel® 152a 7.5 15
Water 15 7.5
Cost of 8oz
can
R
Reference
1.1R 1.21R
82. AEROSOL TECHNOLOGY
55% VOC Hair Spray Formulation(Wt%)
Performance Brand
Resin 5 5
Ethanol 35 35
Hydrocarbon
Dymel® A 20 20
Dymel®
152a
10 15
Water 30 25
Cost of 8oz
can
1.08R 1.15R
83. AEROSOL TECHNOLOGY
55% VOC Hair Spray Formulation(Wt%)
Salon Brand
Resin 5 5 5
Ethanol 55 55 55
Hydrocarbon
Dymel® A
Dymel® 152a 20 25 30
Water 20 15 10
Cost of 8oz
can
1.21R 1.28R 1.35R
96. AEROSOL TECHNOLOGY
Filling Methods – Comparison
Under
the Cap
Through
the
Valve
Filling Accuracy - +
Filling Speed + -
Filling Range + -
Equipment Utilization + -
Propellant Loss - +
Propellant in Dip Tube + -
97. AEROSOL TECHNOLOGY
USA Regulatory Agencies:
1. Department Of Transportation (DOT)
2. Environmental Protective Agency (EPA)
3. Food, Drug & Cosmetics Administration (FD&CA)
4. Consumer Product Safety Commissioner (CPSC)
5. Federal Labeling & Packaging Act – Fair Packaging
Labeling Act (FPLA)
98. AEROSOL TECHNOLOGY
USA Regulatory Agencies
6. National Bureau Of Standards (NBA)
7. Federal, Insecticide, Fungicide &
Rodenticide (FIFR)
8. Air Transportation Of Aerosols (IATA)
9. US Post Office – Dept. regulations of
Aerosols
Mac Bhuta
99. AEROSOL TECHNOLOGY
WARNING STATEMENTS FOR AEROSOLS
1.FD&CA
2.CPSC
WARNING: FLAMMABLE. CONTENTS UNDER
PRESSURE. DO NOT PUNCTURE OR
INCINERATE. DO NOT STORE AT
TEMPEARTURE ABOVE 120ºF. KEEP OUT
OF REACH OF CHILDREN.
3.NO SYMBOLES AS EUROPE & CANADA
Mac Bhuta
100. AEROSOL TECHNOLOGY
LABELING FOR FLAMMABLE AEROSOL
Mac Bhuta
Flammability Statement
Flash Point Required Text
(A) Pressurized Containers
Flash point at or below
20ºF or if there is a
flashback at any valve
opening
Extremely flammable.
Contents under pressure.
Keep away from fire,
sparks, and heated
surfaces. Do not puncture
or incinerate container.
Exposure to temperature
above 130ºF may cause
bursting [40 CFR 156.78]
101. AEROSOL TECHNOLOGY
LABELING FOR FLAMMABLE AEROSOL
Mac Bhuta
Flammability Statement
Flash Point Required Text
(A) Pressurized Containers
Flash point above 20ºF and
not over 80ºF or if the
flame extension is more
than 18 inches long at a
distance of 6 inches from
the flame
Flammable. Contents under
pressure. Keep away from
heat, sparks, and open
flame. Do not puncture or
incinerate container.
Exposure to temperature
above 130ºF may cause
bursting
[40 CFR 156.78]
102. AEROSOL TECHNOLOGY
LABELING FOR FLAMMABLE AEROSOL
Mac Bhuta
Flammability Statement
Flash Point Required Text
(A) Pressurized Containers
All other pressurized
container
Contents under pressure.
Do not use or store near
hat or open flame. Do not
puncture or incinerate
container. Exposure to
temperature above 130ºF
may cause bursting
[40 CFR 156.78]
103. AEROSOL TECHNOLOGY
LABELING FOR FLAMMABLE AEROSOL
Mac Bhuta
Flammability Statement
Flash Point Required Text
(B) Non Pressurized Containers
At or below 20ºF
Above 20ºF and not over 80ºF
Above 80ºF and not over 150ºF
Extremely flammable. Keep
away form fire, sparks, and
heated surfaces.
Flammable. Keep away from heat
and open flame
Combustible. Do not use or
store near heat or open flame.
[40 CFR 156.78]
104. AEROSOL TECHNOLOGY
FEDERAL PACKAGING –FAIR PACKAGING LABELING ACT
1. Aerosol Package Must Be Labeled In Units Of
WEIGHTS E.G. Net Wt. 12.0 Oz. – Front Panel
2. Over One Pound Declaration Must Be In Ounces Followed
In Parentheses By Declaration In Whole Pounds. E.G.
Net Wt.
18 ½ Oz.(1 Lb 2 ½ Oz.) Front Panel
3. SUPPLEMENTARY CONTENTS STATEMENTS MAY BE
MADE SUCH AS Fl. Oz. But Not On Front Panel Only
Back Panel.
Mac Bhuta
105. AEROSOL TECHNOLOGY
NATIONAL BUREAU OF STANDARD
1.Checking Net Weight Of Aerosols
2.It Must Deliver To The Consumer
The Stated Net Contents
Mac Bhuta
106. AEROSOL TECHNOLOGY
DEPARTMENT OF TRANSPORTATION
DOT 2N – (40psig – 140psig @ 130ºF)
DOT 2P - (141psig – 160psig @ 130ºF)
DOT 2Q – (161psig – 180psig @ 130º)
EACH COMPLETED AEROSOL CONTAINER FILLED FOR SHIPMENT
MUST HAVE BEEN HEATED UNTIL THE PRESSURE IN THE
CONTAINER IS EQUIVALENT TO THE EQUILIBRIUM PRESSURE
OF THE CONTENT AT 130ºF WITHOUT EVIDENCE OF LEAKAGE,
DISTORATION OR OTHER DEFECT.
AEROSOLS – CONSUMER COMMODITY – ONLY SHIPPED BY AIR.
Mac Bhuta
108. AEROSOL TECHNOLOGY
VOC Regulations
Mac Bhuta
• HVOV: High Volatility Organic Compound
• MVOC: Medium Volatility Organic Compound with
vapor pressure > 2 mm Hg @ 20º C & less
than or Equal to 80 mm Hg @ 20º C
• > 55% VOC Hair sprays-To be sold in California ended
12/31/99. All Non-Compliant Products had to be of the
shelves by 12/31/2002
• >6% VOC Mousses sold in California ended 12/31/2002.
The 3 year “Sell Through” period must be off the
shelves is 12/31/2005
• There are 13 States will follow OTC( Ozone Transport
Commission ) Model when it takes effect in 2005
109. AEROSOL TECHNOLOGY
VOC Regulations
Mac Bhuta
•There are 13 States will follow OTC
( Ozone Transport Commission ) Model
when it takes effect in 2005
Connecticut Delaware
Dist. Of Columbia Maine
Maryland Massachusetts
New Hampshire New Jersey
New York Pennsylvania
Rhodes Island Vermont
Virginia
110. AEROSOL TECHNOLOGY
VOC Regulations – As of 12/31/2006
Mac Bhuta
PRODUCT VOC LIMIT %
Adhesive Removers
1.Floor & Wall Covering Adhesive 5
2.Gasket or Thread Locking Adhesive 50
3.General Purpose Adhesive 20
4.Special Adhesive 70
Contact Adhesive
1. General purpose 55
2. Special Purpose 80
Anti-Static Product
1. Non – Aerosol 11
Electronic Cleaner 75
Electrical Cleaner 45
111. AEROSOL TECHNOLOGY
VOC Regulations – As of 12/31/2006
Mac Bhuta
PRODUCT VOC LIMIT %
Fabric Refresher
1. Aerosol 15
2. Non-Aerosol 6
Footwear & Leather Care Product
1. Aerosol 75
2. Solid 55
3. All other Forms 15
Graffiti Remover
1. Aerosol 50
2. Non – Aerosol 30
Hair Styling Product
1. Aerosols & Pump Sprays 6
