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Continuous Spray & Aerosol Concepts

Bag-on-valve and aerosol filling for sunscreen, self-tan mist, and other continuous-spray formats: no-touch, even-coverage application customers already prefer.

13 Concepts in this format. InSpec can develop a target product profile in this format even if it's not shown here.

How bag-on-valve continuous spray works

In a bag-on-valve (BOV) can, the formula fills a sealed inner bag and compressed gas, nitrogen or compressed air, surrounds it. Product and propellant never touch. The formula carries no propellant, the can sprays at any angle including upside down, and the air-free seal helps protect active ingredients over shelf life.

Consumers like the format for even, full coverage with no rubbing in, and the bag empties almost completely. That preference is why continuous spray carries a $1 to $4 retail premium over equivalent pumps, and why shoppers who switch tend to stay with it. Few US contract manufacturers run commercial BOV. InSpec fills it in-house, from can fill and valve crimp to gas charge and fill-weight QC.

See the manufacturing side: Bag-on-valve and aerosol manufacturing →

What to settle before you quote

  1. What runs on the line

    Spray SPF, setting and facial mists, wound wash, pain relief sprays, body sprays, and mineral or fragrance-free baby formulas. Share your formula type and texture early so spray pattern and coverage can be confirmed during development.

  2. Drug or cosmetic

    Sunscreen, topical pain relief, and skin protectants like colloidal oatmeal are OTC drugs: they need a monograph-compliant formula and a Drug Facts panel. Mists and body sprays are usually cosmetics. The path you're on shapes testing and labeling.

  3. Stock formula or tech transfer

    Start from a formula in our library or bring your own for tech transfer. Tell us your target annual volume and we'll talk timelines and minimums for the can and valve you choose.

  4. Checked unit by unit

    Every unit is weighed and checked for spray consistency, and out-of-spec units are pulled before they leave the line.

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