Eco-Friendly Aerosol Manufacturing Services

At Hydrokem, we offer a range of environmentally conscious propellant options, including compressed air and nitrogen, which are both inert, non-flammable and significantly lower in global warming potential than traditional hydrocarbon-based gases like butane and propane. These alternatives still provide effective product delivery while greatly reducing the carbon footprint associated with aerosol products. Choosing these greener propellants is a key step in aligning your brand with increasingly stringent environmental regulations and rising consumer demand for sustainable solutions.

Yes, most aerosol packaging—especially when made from aluminium or tinplate—is fully recyclable through standard recycling channels in the UK and EU. Hydrokem prioritises the use of such materials in our manufacturing process. Additionally, we help clients choose recyclable caps, valves, and labelling options. It’s important to note that recyclability also depends on consumer behaviour and clear labelling. We offer support on how to label and package products to encourage proper disposal and recycling, helping reduce landfill waste and close the loop on packaging lifecycle.

Bag-on-Valve (BOV) technology offers multiple environmental advantages. First, it separates the product from the propellant, allowing for the use of cleaner gases like air or nitrogen. Second, it enables almost complete evacuation of the product, reducing waste and maximising efficiency. Third, BOV packaging is often made from recyclable materials. It also eliminates the need for preservatives in many formulations due to its air-tight nature, making it ideal for natural and organic products. BOV enhances shelf life, improves user experience, and aligns with modern sustainability goals—making it an increasingly popular choice across personal care, healthcare, and pet care sectors.

Hydrokem offers end-to-end support to help brands create or convert products into eco-friendly aerosol formats. This includes formulation guidance with non-toxic and biodegradable ingredients, selection of sustainable propellants, and sourcing of recyclable or reusable packaging. We also provide advice on eco-labelling and compliance with environmental certifications, such as ISO 14001 or COSMOS where applicable. Our in-house technical team works closely with your brand to ensure your product not only meets performance expectations but also aligns with sustainability principles from production to post-consumer use.

The cost of manufacturing eco-friendly aerosols can be slightly higher than traditional methods, primarily due to the sourcing of sustainable ingredients and packaging components. However, this is increasingly offset by consumer willingness to pay a premium for sustainable products, as well as cost savings from reduced waste and improved production efficiencies. Moreover, using environmentally responsible practices can enhance your brand image, support regulatory compliance, and future-proof your product range. At Hydrokem, we work with clients to develop solutions that balance sustainability, performance, and cost-efficiency.