United States
               Environmental Protection
               Agency
Air and Energy Engineering
Research Laboratory
Research Triangle Park NC 27711
               Research and Development
EPA/600/S2-91/056 Dec. 1991
EPA       Project  Summary
               Manual for  Non-CFC Aerosol
               Packaging:  Conversion from
               CFC  to  Hydrocarbon Propellants

               K.M. Adams, K.E. Hummel, T.P. Nelson, and S.L. Wevill
                  Because stratospheric ozone pro-
               vides protection from biologically dam-
               aging  ultraviolet-B  radiation, and
               because chlorofluorocarbons (CFCs)
               have been strongly implicated in the
               thinning of the Earth's stratospheric
               ozone layer, there is an urgent need to
               eliminate production  and use of the.
               CFCs. In the U.S., CFCs were banned
               for use as propellants from nearly all
               aerosol products as early as 1978. In
               place of the CFC propellants, liquefied
               hydrocarbons such as propane, n-bu-
               tane, and isobutane were found to be
               acceptable substitutes for the majority
               of aerosol products.  This report pro-
               vides technical assistance to aerosol
               product marketers and fillers  in other
               nations now faced with eliminating CFCs
               under the terms of the Montreal Proto-
               col. The report addresses the Issues of
               hydrocarbon propellant supply, prod-
               uct reformulation, equipment  conver-
               sion, and safety concerns for both the
               manufacturing plants and the aerosol
               products themselves.
                  This Project Summary was devel-
               oped by EPA's Air and Energy Engi-
               neering Research Laboratory, Research
               Triangle Park, NC, to announce key find-
               ings of the research project that Is fully
               documented in a separate report of the
               same title (see Project Report ordering
               information at back).

               Introduction
                  Recent concern about depletion of the
               stratospheric ozone layer has focused on
               synthetic chemicals known as chlorofluo-
 rocarbons (CFCs).  Scientists have con-
 cluded that destruction of the ozone layer
 by CFCs will allow too much harmful ultra-
 violet radiation to reach the Earth's sur-*
 face, with  potentially catastrophic results.
 The most serious consequences include a
 higher incidence of skin cancer and cata-
 racts, suppression of the human immune
 system, damage  to  plant and animal life,
 and global warming.
    In response to these concerns, coun-
 tries around the world have agreed to phase
 out the production and use of CFCs by the
 year 2000. The Montreal Protocol, drafted
 under the  auspices  of the United Nations
 Environment Programme (UNEP), has
 been ratified as  of  October 1990 by 68
 countries  and the  European Economic
 Community (EEC). Work is now underway
 to find substitutes and alternatives to re-
 place CFCs, as well as to decrease CFC
 emissions in areas  for which substitutes
 are currently unavailable.
    Many alternatives exist for replacing
 the CFC-propelled aerosol package. This
 manual does  not discuss the strengths
 and weaknesses of the many potential
 options. A brief list of the alternatives, how-
 ever, follows:
  •  Hydrocarbon propellants;
     Other liquefied gas propellants such
     as dimethyl ether (DME);
     Compressed gas propellants such as
     carbon  dioxide, nitrous oxide, and
     nitrogen;
     Hydrochlorofluorocarbons (HCFCs)
     such as HCFC-22, HCFC-123, and
     HCFC-142b;
                                                               Printed on Recycled Paper

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 •   Hydrofluorocarbons (MFCs) such as
     HFC-152a and HFC-134a; and
 •   Non-aerosol packaging such as me-
     chanical finger pumps, trigger spray-
     ers, and other alternative packaging.
   This manual provides manufacturers of
aerosol products with the technical infor-
mation that will  enable them to convert
from CFC propellants to hydrocarbon pro-
pellants. Hydrocarbon propellants are pri-
marily  mixtures (or pure components) of
butane and propane, along with pentane,
and to  a much lesser extent,  ethane.
   For the reasons listed below, if manu-
facturers choose to continue to use aero-
sol dispensers  instead  of  non-aerosol
alternatives, hydrocarbon propellants are
the most feasible near-term alternative to
CFC aerosol propellants:
 •   Hydrocarbons can  be  treated and
     blended to obtain the physical and
     chemical properties that make them
     suitable aerosol propellants;
 •   Most hydrocarbons are essentially
     nontoxic, making them suitable for
     use in a variety of personal care and
     household products;
 •   Hydrocarbon propellants are less ex-
     pensive than CFCs, enabling manu-
     facturers to produce aerosols at a
     tower unit cost;
 •   Hydrocarbons are compatible with
     properly selected container materi-
     als and formulations, thus preserving
     shelf life and product stability; and
 •   Since the banning of  CFC aerosol
     propellants,  hydrocarbons  have be-
     come the dominant aerosol propel-
     lant   in  many  developed  and
     developing  countries and  useful ex-
     perience  is available that can mini-
     mize the conversion cost  for other
     countries.
   Hydrocarbons also have two limitations
or disadvantages:
 •   Hydrocarbon propellants  are flam-
     mable; therefore, precautions must
     be taken by producers, distributors,
     and  end-users  to  ensure that  the
     aerosol products are handled safely.
 •   Hydrocarbon propellants belong
     in a  class of compounds known
     as volatile  organic  compounds
     (VOCs),  which are  natural  and
     synthetic compounds that contrib-
     ute to the  formation  of what is
     known as photochemical "smog."
     In some urban areas where smog
     formation  is a  health and  envi-
     ronmental   problem,   regulations
     have been proposed to reduce
     the  amounts of  VOCs  in con-
     sumer products.
 Properties and Availability of
 Hydrocarbon Propellants
   A replacement aerosol propellant must
 have properties that allow the aerosol pack-
 age  to function: 1) the aerosol propellant
 must provide the pressure to expel the
 product from the container; 2) the propel-
 lant  may serve as a solvent to aid in keep-
 ing the  active ingredients in solution; and
 3) the propellant must vaporize after leav-
 ing the container,  producing a spray or
 foam. Other important properties of aero-
 sol propellants are toxicity, stability, den-
 sity  and flammability. Table  1  compares
 the properties of the most common CFC
 propellants (CFC-11 and CFC-12) and the
 hydrocarbon propellants (isobutane, n-bu-
 tane, and propane).
   Either liquefied gases or  compressed
 gases can provide pressure to expel prod-
 uct from the container. Hydrocarbon and
 CFC aerosol propellants are both liquefied
 gases. Throughout the life of the aerosol
 product, they  generally provide a more
 uniform internal pressure.
   The  solubility of the propellant is impor-
 tant  since it determines whether the over-
 all contents  are  uniformly  blended
 ("homogeneous"), or whether the contents
 exist in separate phases ("heterogeneous").
 The  hydrocarbon compounds are all non-
 polar, which renders them insoluble with
 many polar solvents (including water). How-
 ever, in some cases  co-solvents such  as
 ethanol can be used to provide single-
 phase  blends  of  hydrocarbons, alcohol,
 and water.
   The toxicity of propellants may be com-
 pared by using the threshold limit value
 (TLV, a trademark of the American Confer-
 ence of Governmental Industrial Hygien-
 ists—ACGIH).  The TLV is the maximum
 level of exposure for a person working 8
 hours a day, 40 hours a week throughout a
 normal  working career without  adverse
 health effects. The occupational exposure
 guidelines for CFC-11, CFC-12, and  hy-
 drocarbon propellants are roughly compa-
 rable.
   The corrosion properties of propellants
 may be compared by testing their hydro-
 lytic stability. These tests measure the rate
 of hydrolysis (decomposition) in the pres-
 ence of a steel test coupon in water. CFCs
 are generally less stable than the hydro-
 carbons. However, contaminants in "field-
 grade"  hydrocarbons  (water, and  sulfur
 compounds) may have a major effect on
 corrosion.
   No discussion of the properties of hy-
 drocarbons would be complete without con-
 sidering flammability. The flammability of
 an aerosol spray is a combined function of
the composition of the product inside the
container and of the design of the valve.
Frequently, other major ingredients of the
formula (e.g., alcohols or petroleum distil-
lates) are also flammable.
   Hydrocarbon propellants are derived
from  liquefied  petroleum gases  (LPGs)
which come from the ground as constitu-
ents of wet natural gas or crude oil or as a
by-product of petroleum refinjng. LPG usu-
ally  refers to  a mixture  of propane and
butane, although other hydrocarbons may
also be present (ethane  at the light end,
and  pentanes  at the  heavy end). The
amount of LPG used for aerosol propellant
is very small (less than 0.1% in the U.S. in
1981). Aerosol grade hydrocarbon propel-
lants are prepared  by first distilling  the
LPG to separate the various species. The
distillation of hydrocarbon  propellant is nor-
mally carried out at a specially designed
plant that serves the regional aerosol in-
dustry.  These plants are generally quite
sophisticated and would  be too large for
any single aerosol filler.
   Some aerosol products may  use so-
called "natural blend" LPG instead of dis-
tilled hydrocarbons. The primary advantage
of natural blend LPG is that it is  less ex-
pensive because there is less processing
of the hydrocarbon. The natural blend pro-
pellant is suitable in products where odor
is not as important (i.e., where the concen-
trate itself is quite odorous as in some
degreasers or spray paints) or where the
spray characteristics  are not critical (such
as wet sprays in some  residual  insecti-
cides). A disadvantage of  natural blend
hydrocarbon propellant is that the quality
varies, resulting in  inconsistent pressure.
Because the natural blend is produced by
a coarse distillation,  the  amount  of pro-
pane,  butane, and  pentanes may differ
from one lot-to the next, and this will affect
the spray pattern.  Natural  blend  propel-
lants are likely to contain  larger quantities
of impurities (such as water, sulfurous com-
pounds,  olefins, or reactive particulates).
The presence of water can be tolerated in
water-based products, but not in products
intended to be anhydrous.
   Some types  of aerosol products re-
quire a purer hydrocarbon propellant than
other types. The most demanding aerosol
products are aerosol perfumes and fra-
grances. Other products  which require a
highly refined hydrocarbon  propellant in-
clude personal care products, food prod-
ucts, medicinal or pharmaceutical products,
some household products, certain paints
and coating sprays, and  certain automo-
tive and industrial sprays.
   Before the propane and butanes are
suitable for these aerosol  propellant appli-
cations, they must be purified further to

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 Table 1.
Physical Properties of CFC and Hydrocarbon Propellants


Name

CFC-11
CFC-12
Propane

Isobutane

n-Butane



Formula

CCI3F
CCIf,
C3H$

C4H10

CtHw



Molecular
Weight

137.4
120.9
44.1

58.1

58. 1


Vapor
Pressure
@21°C
(kPa)
89
586
855

317

221



Specific
Gravity

1.476
1.311
0.5077

0.5631

0.5844

Solubility
in Water
(Kauri-
Butanol)

60
18
15.2

17.5

19.5



Toxicity
(TLV)

9 1000
1000
1000
'
800 (est.)
_
600

Stability
(g/L per year)
(w/steel 30PC,
101.3 kPa)

10
0.8
—

—

—



Flammability
(explosive range)

Nonflammable
Nonflammable
Flammable
(2.18 - 9.5 vol%)
Flammable
(1.86- 8.5 vol%)
Flammable
(1.86 - 8.5 vol%)
remove odorous and reactive compounds
such as unsaturated hydrocarbons (for ex-
ample, 1-butylene or propylene), as well
as sulfur compounds and water. The pro-
cesses used include: dehydration (for re-
moving  moisture); acid  gas removal (for
removing sulfur compounds); and sulfuric
acid treatment or desiccant treatment (for
removing unsaturated compounds). Con-
tacts with industry experts and limited pub-
lished data suggest that the most common
type of hydrocarbon propellant purification
is the solid adsorbent process.  The solid
adsorbent process can use such materials
as silica gel, activated aluminas, or mo-
lecular sieve adsorbents for water or sulfur
compounds (dehydration or acid gas re-
moval).  Unsaturated compounds can be
removed using activated carbon or mo-
lecular sieves. The nonregenerable  sys-
tem is simpler and less expensive than a
regenerable system,  but the adsorbent(s)
must be replaced periodically. The disad-
vantage of a non-regenerable adsorbent
system  is that, once the adsorbent be-
comes saturated,  the impurities will no
longer be removed, and contaminated pro-
pellant will enter the system.
   An alternative to on-site purification is
to use a central purification facility in con-
junction with a distillation system. The cen-
tral purification facility can operate  with
multiple beds that are alternated between
purification  and regeneration. Such a com-
bined facility would  comprise the basic
elements of a regional hydrocarbon  pro-
pellant supply.
   Countries can import purified  hydrocar-
bon propellant or LPG by overland or ocean
shipment in bulk containers. Containers for
shipping LPG include tank trucks, rail tank
cars, and containerized  pressure vessels
(International Organization of Standardiza-
tion containers) for ocean shipment.
                              Safety in Using Hydrocarbon
                              Propellants
                                 Hydrocarbon gases are used primarily
                              as fuels. Because of their flammability,
                              they must be handled with great care. In
                              the U.S., the National Fire Protection As-
                              sociation (NFPA) has  issued standards for
                              manufacturing  and storing aerosol prod-
                              ucts (NFPA Code SOB),  and for  storing
                              and handling LPG (NFPA Code 58). In
                              addition to these codes, which relate di-
                              rectly to  the safety of aerosol products,
                              many other NFPA codes are relevant. Im-
                              portant safety measures include:
                                   Locating manufacturing buildings and
                                  flammable propellant storage tanks
                                   at a safe distance [7.6 m (25 ft) or
                                   more] from the property fenceline and
                                  from other areas  of the  plant that
                                  could become sources of ignition or
                                  shrapnel.
                                  Providing for a  blast wall between
                                  flammable propellant charging rooms
                                  and other areas.
                                  Providing a well-ventilated gas house
                                  that gives positive ventilation (at both
                                  normal and emergency rates).
                                  Routing all discharge vents from
                                  vacuum pumps, propellant pumps,
                                  and building ventilation systems no
                                  less than 3 m (10 ft) above the roof to
                                  ensure adequate dispersion.
                                  Complying with  the  1990 U.S. Na-
                                  tional Electrical Code (NEC) for haz-
                                  ardous atmospheres, which requires
                                  that equipment  be isolated so that
                                  these  potential ignition sources are
                                  enclosed  in "explosion proof" hous-
                                  ings. The NEC  Code specifies that
                                  approved fixtures be used on electric
                                . motors, switches, lamps, and other
                                  electrical  equipment.  The minimum
      ratings for the gas house and pump
      room where flammable hydrocarbon
      propellants are used are Class I, Di-
      vision 1, Group D.
      Installing blowout walls or ceiling ("de-
      flagration venting") to allow a con-
      trolled  release of pressure if  an
    .  explosion occurs. If venting  is  not
      possible or if personnel will be present
      when filling is underway, a specially
      engineered "explosion suppression"
      system is required. This type of sys-
      tem often employs pressurized halon,
      which is  an ozone-depleting sub-
      stance, and  its production will  be
      phased out under the Montreal Pro-
      tocol.
      Providing automatic sensing systems
      to measure flammable gas concen-
      trations  in the  gas house, sound
      alarms, and activate the emergency
      ventilation system and interlocks to
      cut off the propellant supply from the
      tank farm.
Again, this is only a partial list of the Code
requirements. Other important areas cover
such  topics as fire  sprinkler  systems,
standpipes, fire hoses, and fire extinguish-.
ers.
   A  fully enclosed gas house  with two-
speed ventilation  and an  explosion sup-
pression system may  not be necessary in
warm climates, where an "open-air filling"
area may be possible. The open-air filling
technique has several advantages,  such
as reduced capital expenditures for install-
ing or retrofitting an aerosol-filling plant.
   In  addition to the general safety consid-
erations for hydrocarbon storage and build-
ing construction, other engineering safety
measures apply to the hydrocarbon con-
tainer valves and accessories, piping, and
safety relief devices.

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Labeling Requirements and
Flammabillty Testing
   Manufacturers normally place warnings
on labels  of aerosol products to  ensure
that the products are used safely and for
thoir intended purposes. Among the most
important labeling statements are the words
FLAMMABLE and EXTREMELY  FLAM-
MABLE. These warnings do not generally
discourage purchases of useful products
except on baby products, foods, and some
Pharmaceuticals.
   In the U.S., two tests are used to deter-
mine when FLAMMABLE or EXTREMELY
FLAMMABLE labels are required: 1) the
Modified Flash Point Test, and 2) the Flame
Projection/Flashback Test.

Equipment Conversion of
Hydrocarbon Filling Operations

Automated Filling Lines
   The large aerosol filling operation uses
an automated production line that can pro-
duce 14,000 to 28,000 units per shift, which
equals approximately 35 to 70  units per
minute. The equipment that must be modi-
fied to convert from CFG aerosols includes
the propellant supply, the gassing area,
and  possibly the main  production area,
depending  on the location of the gassing
area.
   Automated filling lines typically use bulk
storage of the hydrocarbon propellant. One
of the most important guidelines is ensur-
ing that the distance between the tanks
and  charging pumps and the production
and gassing area meets the specifications
in NFPA 30B. For tanks under 7.6 m3 (268
ft3), at  least 8 m (25 ft)  from the nearest
production facility  is recommended.  For
tanks over 7.6 m3, at least 15 m (50 ft) is
recommended.  If  existing fixed storage
tanks are reused, they must be thoroughly
cleaned (sandblasted) and hydrostatically
tested  at 2 times their maximum working
pressure to ensure they can safely store
the hydrocarbon  propellant.
   In addition to the storage area, modifi-
cations may be  needed for the gassing
and  production areas. The gassing room
should be  constructed  outside  the main
production area. The modifications required
include increased ventilation, combustible
gas detectors, isolation of electrical equip-
ment in "explosion proof" housings, and
possibly an explosion suppression system.
The walls and roof of the gas house should
be made blast proof, and blowout panels
should be  provided to allow a controlled
release of  pressure.
   If a facility is not  able to  make  the
modifications suggested above, then an
open-air gassing room may be an alterna-
tive. The main feature of the open-air gas
house  is the  use of natural ventilation to
keep  any escaped hydrocarbon  vapors
below flammable or explosive limits. The
gassing apparatus is located outside of the,
main production facility, with  a solid roof,
wire mesh walls on three sides, and a solid
wall between  the gassing area and the
main production facility.
   The costs for converting an automated
aerosol filling line are difficult to estimate
without site-specific details. One example
is the Mexico Case Study, which estimated
the cost to convert an automated filling line
(producing 8  million cans per year) from
CFCs to LPG to be  $566,000 for capital
investment (machinery and filling lines) and
$793,000 for auxiliary equipment (gas de-
tectors, fire  extinguishing  systems, and
alarms),  resulting in a conversion  cost of
$1.36 million U.S.  dollars. However, the
estimated propellant savings from using
less expensive hydrocarbons in place of
CFCs  would  be $1.69  million U.S. per
year. Therefore, the cost savings from con-
verting to hydrocarbons would more than
offset the initial capital investment.

Manual Filling Lines
   Small- to  medium-sized aerosol-filling
operations typically use a manual produc-
tion line  capable of producing  6,000 to
8,000 units per shift with two persons (lim-
ited to filling, gassing, crimping only), which
would  equate to approximately 15  units
per minute. On the basis of one 8-hour
shift per day and a 5-day work week, such
a plant could conceivably produce nearly 2
million units per year. Other operations,
such as labeling containers with paper la-
bels or packing, would either slow the rate
or require additional labor.
   Atypical manual aerosol filling line uses
air-operated and manually actuated equip-
ment. Each container must be transferred
manually from one step to the next. Cold
filling is nor appropriate with  hydrocarbon
propellants and should be replaced by pres-
sure filling. A single-station pressure filling
machine  may cost up to $30,000.
    Required  equipment  modifications
would typically be limited to the propellant
supply and the gassing area. The hydro-
carbon storage used for small manual fill-
ing lines are typically several 53-kg (117-lb)
cylinders manifolded together or a 385-kg
(849-lb)  container. Cylinders not  in  use
should be stored in the open air or in well-
ventilated areas. No  more than six cylin-
ders should  be stored together  with  a
minimum distance of 3 m (10 ft) between
the storage and a  boundary, building, or
fixed ignition source (such as pumps, elec-
trical  motors,  or  vehicles). All  cylinders
should be stored upright, with protective
valve caps in place, and securely chained.
   In addition to the propellant supply,
equipment modifications for manual lines
must be made to the gassing  area. Many
small filling operations  are  located in
crowded urban areas, and the use of an
open-air gassing area would not be pos-
sible. One way to significantly reduce the
hazards associated with hydrocarbon pro-
pellants would be to locate the gassing
and crimping operations within  a labora-
tory  fume hood.  These types  of hoods
have been successfully  used for labora-
tory-scale, manual filling operations that
closely correspond to cottage-size produc-
tion facilities.
   The exhaust from the fume hood should
be connected  to a flue or pipe  duct that
uses an explosion-proof fan  motor. The
end of the duct or piping should exit di-
rectly through the roof of a one-story build-
ing or to an adjacent outside wall if the
filling room is located in a multi-story build-
ing. The location  of any ignition sources
that may be near the exhaust  duct should
be considered. The fume hood, fan-motor,
and any equipment used within  the fume
hood (such as lighting) should be Class I,
Division 1, Group D explosion-proof equip-
ment.
   The costs for converting a'manual aero-
sol filling line are also difficult to estimate
without site-specific details. The estimated
cost to convert a hypothetical manual fill-
ing line (producing 500,000 cans per year)
from CFCs to LPG is at least $12,000 U.S.
dollars. This includes purchase  of explo-
sion-proof motors, starters, and solenoid
valves; installation of explosion-proof fume
hoods for gassing equipment  and test
baths; and  construction of  a  covered,
fenced hydrocarbon storage area. This ini-
tial capital investment would be more than
recovered by the material cost savings of
using hydrocarbon propellants instead of
CFC propellants.

Aerosol Product Storage
   Since hydrocarbon propellants are flam-
mable  (containing  butane, propane, or  a
mixture of- these two, or less frequently,
pentane or  ethane), producers, distribu-
tors, and end users must take extra care to
handle them safely. Aerosol products can
be classified into three levels according to
their perceived flammability. hazard. The
classification considers the percentage of
flammable base material and flammable
propellant. Materials that mix with water,
such as ethanol, isopropanol, propylene
glycol, and acetone, would dissolve in the
water from sprinklers and fire hoses during

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afire and be rendered nonflammable. Wa-
ter immiscibje materials, on the other hand,
such as toluene and aliphatic petroleum
distillates  would not dissolve  and could
spread as a burning top layer as water was
directed at a fire.
   Level  1 aerosol  products  are those
whose base products contain  up to 25%
by weight of materials with flash points of
260°C (500°F) or less. Level 1 aerosol
products do not require special  fire pro-
tection measures. These "water-based"
aerosol products  may  be stored as a
Class III commodity as defined in NFPA
Standard 231 for Rack Storage of Materi-
als;  i.e., equivalent to paper, cardboard,
and  wood products.
   Level 2 products are those whose base
product contains either 1) more than 25%
by weight  of water miscible materials with
flash points of 260°C (500°F) or less, or 2)
more than 25% but less than 55% of water
immiscible materials with  flash points of
260°C  (500°F) or  less. Level 3 products
are those whose base product contains
more than 55% of water miscible materials
with  flash points of 260°C (500°F) or less,
or the flammable propellant equals or ex-
ceeds 80% of the net container weight.
   Level 2 and Level 3 aerosol products
may be stored in a general purpose ware-
house that either has no sprinklers or is
not protected  in accordance with  NFPA
306, but the quantity is limited to  1135 kg
(2,500  Ib). Storage of greater amounts of
Level 2 and Level 3 aerosol products in
general purpose warehouses requires com-
pliance with the protection guidelines for
automatic sprinklers and palletized, solid
pile, or rack storage arrangements as listed
in NFPA 30B.
   Aerosol 'storage in sales display areas
and backstock storage areas is also ad-
dressed in NFPA 306.

Product Reformulation
   The characteristics of hydrocarbon pro-
pellants as they relate to formulations and
performance  are discussed.  Dispersion,
one major attribute of aerosol propellants,
is the  efficiency with which a propellant
can produce  a fine spray or acceptable
foam. The dispersive effect is not linear
but is  modified  by vapor  pressure  and
solubility factors, ft normally can be used
as a general guideline to determine equiva-
lencies when changing from one propel-
lant to another.
   After a  concentrate  has been  tenta-
tively  developed, the correct type  and
amount of propellant must be added, and
an aerosol valve must be used that will
develop the desired spray pattern or foam
puff. One of the most important character-
istics that the formulator looks for is par-
ticle size distribution. There are several
techniques to decrease the droplet size if it
is too coarse.  One approach is to  use a
vapor-tap valve.
   Approximately 40-50% of the world's 8
billion aerosol products  use vapor-tap
valves.  Such valves have  an orifice ex-
tending through the side or bottom wall of
the valve body and into the  head space
area. The orifice may be enlarged to de-
crease  particle size.  However, this has
several negative effects.
   To devise a good aerosol product, a
formulator must minimize the risks of flam-
mability and possible explosivity. It is a
tribute to the  excellence  of  the  aerosol
packaging form that extremely flammable
products can be safely dispensed,  if the
user follows label directions, and if the
formulator is able to make allowances for
reasonably foreseeable consumer misuse.
   Most U.S. aerosols are formulated to a
pressure as  low as is consistent with good
operational performance across the antici-
pated temperature range of their use. For
example, hair sprays are expected to work
well between 13°C and 37°C,  and reason-
ably well just outside these limits.
   The formulator's job is not complete
when an acceptable product and packag-
ing system  have been  developed. Test
packing is always needed to establish data
on weight loss rates, can and valve com-
patibility, etc. Several options are discussed
to correct corrosion problems, such as ad-
dition of corrosion inhibitors, increasing the
pH, or minimizing the presence of chloride
ion.
                                                                          •&U.S. GOVERNMENT PRINTING OFFICE: 1992 - 648-080/40119

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    K.M. Adams, K.E. Hummel, T.P. Nelson, and S.L Wevill are with Radian Corp., Austin, TX
      78720-1088
    N. Dean Smith is the EPA Project Officer, (see below).
    The complete report, entitled "Manual for Non-CFC Aerosol Packaging: Conversion from
      CFC to Hydrocarbon Propellants," (Order No. PB92-101344/AS; Cost: $35.00, subject to
      change) will be available only from:
            National Technical Information Service
            5285 Port Royal Road
            Springfield, VA 22161
            Telephone: 703-487-4650
    The EPA Project Officer can be contacted at:
            Air and Energy Engineering Research Laboratory
            U.S. Environmental Protection Agency
            Research Triangle Park NC 27711
United States
Environmental Protection
Agency
Center for Environmental Research
Information
Cincinnati, OH 45268
      BULK RATE
POSTAGE & FEES PAID
 EPA PERMIT NO. G-35
Official Business
Penalty for Private Use $300
EPA/6QO/S2-91/056

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