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Bag on Valve Technology

Putting Your Product Into Superior Bag-on-valve Aerosol Technology

As more companies begin to recognize the benefits of bag-on-valve aerosol technology, we are often asked if bag-on-valve is suitable for their product, and if so, how does the manufacturing process work?

bag-on-valve aerosol filling

I sat down with Daniel Lagerkvist, Aurena Laboratories’ production manager, to talk about the manufacturing process and how various wound care, skin care, nasal spray, cosmetic and even some food products can be evolved into the modern spray dispensing technology of bag-on-valve (BOV). Below are highlights from our discussion:

Magnus Hedman (MH): As production manager, you’ve been involved in many variations of manufacturing for BOV. Can you start off by telling me what types of products are suitable for this type of aerosol?

Daniel Lagerkvist (DL): Bag-on-valve is incredibly versatile with few limitations. Almost all fluids, including liquids, creams and gels, can be filled into a BOV system. The only requirement is that the product’s viscosity is low enough to get it through the valve stem. Also, BOV does not work well with products that need to be shaken before use.

MH: How does the product get into the can?

DL: The secret is inside the can! There is a rolled-up multi-layered flexible pouch attached to an aerosol valve. During production, compressed air or nitrogen is charged into the can, and an aerosol valve with the bag attached is crimped onto the container. The formulation is forced through the aerosol valve stem to fill the bag. Finally, the actuator and cap are put in place.

MH: What about the packaging? Are different sizes available?

DL: Standard BOV packaging covers a broad range of sizes, from 30mL to 500ml containers. Typically, the cans are standard aerosol aluminium cans with 1 inch openings, with an interior foil-based packaging bag. It’s the bag inside the can that makes it superior to other standard aerosol.

MH: How do you maintain product integrity during the production process?

DL: One of the benefits of BOV is the ability to keep the product separate from the propellant. The product in the bag encompasses 60 per cent of the can’s brim capacity, while the remaining 40 per cent is occupied by the propellant. However, the propellant never comes in contact with the product. This ensures the product formulation stays true to its ingredients, without interference from propellants, flammability or too many preservatives.

MH: You’ve done a great job of explaining the manufacturing and filling process of BOV. Once the product is filled, how is it used?

DL: The end-user simply needs to press on the actuator (the spray button). The product is then squeezed out of the bag by the compressed air or nitrogen, and then out comes the spray, cream or gel. No shaking and no fussing with angles.

MH: Thanks for your time and for helping many of our partners put their products into BOV technology.

DL: We are always up for new challenges and continue to be amazed by the endless possibilities with BOV. I look forward to working with many partners in the future.

Interested in finding out how your product could evolve into bag-on-valve spray technology? Contact the Bag on Valve experts for more information.

The next evolution of bag-on-valve: plastic

Bag-on-valve (BOV) is an innovative aerosol spray technology, appealing to those that expect a superior spray with benefits beyond the traditional aerosol. BOV is a spray system that uses a flexible pouch in combination with standard aluminium or tinplate aerosol cans. The limitations to only use standard aerosols cans has prevented some companies from choosing BOV technology, despite recognizing its many benefits.

Introducing PET Aerosol Technology

APPE has recently introduced a plastic alternative to standard aerosol cans. This new technology offers a real alternative for manufacturers seeking a unique branding opportunity that is practical, cost effective and sustainable. The aerosol container, called ‘SprayPET’ is lightweight and offers a lower carbon footprint (up to 65% as stated by APPE).

APPE Aerosols

Other benefits of SprayPET include:

  • Lower weight
  • Lower carbon footprint
  • Easily recyclable
  • Cost effective
  • Lower lifetime cost of ownership
  • No rusting or denting
  • Design and shape flexibility
  • More tactile

In keeping with our commitment to innovation, Aurena Labs will be offering the SprayPET technology for their clients.  Contact Aurena Labs to learn more and to discuss your project.

Bag On Valve: Separating Your Aerosol Product From The Propellants

Many companies spend millions of dollars every year developing, manufacturing and approving their products. Some companies will turn to aerosol packagings to house their healthcare products. But have you ever wondered what is used to drive the product out of the can?

Traditional aerosol cans are designed to mix the propellant with the product. Therefore, what cost your company a lot to develop, manufacture and approve, must then be mixed with a Bag On Valve Spray Canpropellant to dispense your healthcare product.

Bag on Valve, is used as an alternative method to package pharmaceuticals and medical devices. Unlike traditional aerosol packaging, Bag on Valve (BoV) keeps the product separate from the propellant, housing it in a film laminate bag, which is welded to an aerosol valve. Therefore, your precious product maintains its integrity and remains separate from propellants at all times.

How Bag on Valve products are manufactured

Standard BoV packaging covers a broad range from 30 to 500 ml containers. BoV typically uses standard aerosol aluminium cans with 1 inch can openings, together with foil-based packaging bags of four-layer film laminates (for instance PET/ALU/OPA/PE). The film laminate bag is welded to the aerosol valve, which is crimped to the aerosol can in the filling process.

Due to the low permeability rate, BoV is also compatible with commercially available liquefied propellants. These propellants make good choices for products that call for a steady dispensing rate over the life of the can, such as post-foaming gels and creams.

What products are suited for Bag on Valve packaging?

Almost all fluids and more viscous products can be filled into a BoV system, as long as the product’s viscosity is low enough to get it through the valve stem. However, the system does not work well with products that need to be shaken before use, since the bag is filled and doesn’t improve mixing when shaken.

Keeping your product pure

When choosing your next aerosol spray medical device packaging, we suggest you talk to the Bag on Valve specialists and see if your product is best paired with BoV packaging.


Why BoV Packaging is Superior to Traditional Aerosols

BoV vs Traditional Aerosols

Why BoV Packaging is Superior to Traditional Aerosols

To many consumers that enter a supermarket on a daily bases, the quality of an aerosol can may just be another concern that goes overlooked. However, to the industry buyers and manufacturers, an aerosol can can be the difference between an average product and a premium product.

The superior Bag on Valve (BoV) system is developed to not only produce a superior spray dispensing system, but to reduce our ecological footprint through a sustainable packaging process. Compared to traditional aerosol spray technology, BoV aerosols have several benefits for manufacturers, consumers and the environment.

The following are more reasons you should trust BoV as your first choice for aerosols and airless packaging.

Product Emptying – up to 100% product emptying!

Unlike traditional aerosols, BoV keeps product separate from propellants at all times thanks to an FDA-approved laminated bag installed inside the aluminum can. Because the product is in a flexible pouch, the propellant (compressed air or nitrogen) is able to squeeze the bag until almost 100% of the product is dispensed. Unlike traditional aerosols, which may run out of propellant before all of the product is dispensed.


As opposed to flammable propellants used in traditional aerosol systems, BoV uses compressed air or nitrogen to push the product out of the Bag on Valve system. This is possible because unlike traditional aerosols, BoV propellants will not mix with the product.

Product Types

In the medical sector Bag on Valve products are able to dispense as either; liquid, gel, ointment or cream. In some cases, companies can turn their pharmaceutical cream into a spray by using the BoV system. The versatility of BoV even allows products to have several other benefits;

  • Sprayed evenly at all angles

  • No pumping motion required

  • Reduced spray noise

  • Longer shelf life for oxygen-sensitive products

  • Suitable for both liquid and viscous products

  • Can be used with standard actuators and aerosol cans

Production & Environment

Bag on Valve technology is suitable for clean room production and medical products. Companies, such as Aurena Laboratories, incorporate the clean room manufacturing process into their BoV packaging, so they can produce safe and sterile products for customers.

Are you ready to switch from traditional aerosol to Bag on Valve? Contact Aurena Laboratories for more information.


Bag on Valve Medical Devices vs Medicines

What’s the difference between a pharmaceutical and a medical device?

Pharmaceuticals, also known as medicines, are designed to interact with the body’s metabolic or immune system and therefore, take a lengthy amount of time to gain approvals and pass regulatory standards. Medical devices, on the other hand are physical and mechanical in nature and are usually have a shorter approval process. So, by choosing a medical device, products can often make it from the lab to the shelf much quicker.

With regulations becoming much more stringent and the demand for medical devices becomes greater, more companies are turning to Bag on Valve as an innovative solution for their product packaging.

The following is a brief slide show describing the difference between medicines and medical devices and why Bag on Valve is the optimal solution for medical device products.

Are you ready to use Bag on Valve for your medical device packaging? Contact Aurena Laboratories for more information.

Bag on Valve Eye Wash Sprays for Occupational Safety

Studies have shown that exposure to a hazardous substance, in particular a corrosive substance, should be treated within the first ten to fifteen seconds. Even bydelaying treatment by a few seconds could be the difference between a serious injury and a close call.

This is why emergency eye wash stations are becoming more and more mandatory in most workplaces. With the new Eye Wash Sprays in Bag on Valve packaging the high pressure from the aerosol can quickly flushes the hazardous substance out of the eye and reduces the potential for long term damage.

Bag on Valve Eye Wash Sprays

Bag on Valve technology is a modern aerosol spray packaging that allows companies to keep their eye wash product

bag on valve aerosol eyewash

separate from the aerosol propellant at all times, keeping the product that enters their eyes pure.

The following are reasons why Bag on Valve is the number one choice for occupational safety aerosol eye wash sprays:


Custom Label Opportunities for Aerosol Packaging

In the world of over the counter (OTC) medical devices and pharmaceutical aerosols it’s rather difficult to stand out on the shelf of a drugstore or super market – row upon row of aerosol cans will hide a companies product, much like a brick on a wall.

However, Bag on Valve has a solution. Have you considered using Bag on Valve’s custom labelling to catch and hold consumer interest?

Want to learn more about Bag on Valve custom labelling and packaging? Read our blog; Decoration Opportunities with BoV Products.

Recycling of Bag-on-Valve Packaging

Bag on Valve Aluminum CanAccording to the Aluminum Association, recovering aluminum for recycling saves money and dramatically reduces energy consumption. Recycling aluminum cans saves 95 percent of the energy needed to produce aluminum from bauxite ore, as well as natural resources.

Bag on Valve (BoV) packaging stand out from the competition, not only because it is convenient for the end user and keeps the product and propellant separate at the same time, but they are an environmentally sustainable solution for products like medical spray applications.

Aluminum Technology in Bag on Valve Packaging

The BoV packaging is primarily made of aluminum. With a possible emptying rate, close to 100 percent there are virtually no product residues left in an used-up BoV product, while a low pressure of air or nitrogen will remain in the empty can. So, recycling aluminum cans using bag on valve technology is made simple and harmful chemicals don’t make it into the landfills.

Depending on the local regulations for aerosols, recycling of BoV products are handled differently in different states or countries. However, they usually fit into the recycling programmes of most countries. Aluminium has a high recycling value and can be recycled over and over without loss of quality. That’s why approximately 75 percent of the aluminium ever produced is still in use today.

Aluminium recycling requires up to 95 percent less energy and only emits 5 percent of the greenhouse gases than primary aluminium production. Still, aerosol cans are made of virgin aluminium even though they could hopefully be manufactured from recycled aluminium instead.


Medicines and medical devices in Bag-on-Valve

As many of you may already know Bag on Valve (BoV) is a versatile packaging solution, used for a variety of products, from food to medical barrier sprays.

A growing use for the Bag-on-Valve system is with medical products classified as drugs or over the counter medical devices. As opposed to traditional aerosols, BoV maintains your products integrity, keeping your product separated from the propellant at all times. Therefore, customers can trust the quality and consistency of the product when using BoV pharma and medical devices.

Product classifications

In the healthcare marketplace you find products that are classified as:

  • pharmaceuticals

  • herbal products

  • homeopathic remedies

  • cosmetics

  • biocides

  • medical devices (more…)

Manufacturing of BoV Products

Bag-on-Valve (BoV) is a barrier packaging technology for companies with liquid or viscous products, looking to stand out from the competition.

Why not use traditional aerosols? In comparison to traditional aerosols, BoV separates your product from the propellant, keeping your product pure. BoV packaging is 100% recyclable, leaving a low ecological footprint. And most importantly, Bag-on-Valve is convenient and reliable for the end user.

Still not convinced? The following is a brief overview of how companies, like Aurena Laboratories manufacture and package Bag-on-Valve products.

How the Bag-on-Valve manufacturing process works

Bag on Valve Contract ManufacturersStandard BoV packaging covers a broad range from 30 to 500ml containers. Typically, BoV uses standard and fully recyclable aerosol aluminium cans with 1 inch can openings, together with foil-based packaging bags of multi-layer film laminates (for instance PET/ALU/OPA/PP). The bag is welded to the aerosol valve, which is crimped to the aerosol can in the filling process.

When the valve is crimped to the can the propellant, compressed air or nitrogen, is  filled into the area between the bag and the can, keeping product and propellant separate at all times. This pressurising process is called under the cup gassing (UTC). The product in the bag encompasses 60 per cent of the can’s brim capacity, while the remaining 40 per cent is occupied by the propellant.

The benefits of BoV Manufacturing (more…)