Bag-on-Valve (BOV): Advanced Aerosol Technology

What is the Bag-on-Valve (BOV) system?

Bag-on-Valve (BOV) is a revolutionary aerosol packaging technology that completely separates the product from the propellant using a hermetic bag welded to the valve. Unlike traditional aerosols where the product and propellant are mixed, the BOV system keeps the contents pure inside a multi-layer laminated bag, while inert gases such as compressed air or nitrogen provide the pressure necessary for dispensing.

"In a bag-on-valve aerosol, the active ingredient is completely separated from the propellant in a hermetically sealed bag. This allows the product to be applied in its purest form: the complete purity of the formulation is preserved" - TUNAP

Technical components of the BOV system

The Bag-on-Valve system is composed of several specific technical elements that guarantee its optimal operation:

Multi-layer laminated bag: Manufactured with high-barrier materials including layers of aluminum and specialized polymers. This hermetic bag prevents product contamination and oxidation.

Specialized valve: Welded directly to the bag using heat-sealing processes that guarantee the total hermeticity of the system.

Metal container: Generally made of aluminum with a one-inch opening for valve crimping. BOV Solutions confirms that these containers are 100% recyclable.

Inert propellant: Compressed air or nitrogen introduced between the bag and the container walls, creating the pressure necessary for dispensing.

How does the BOV filling process work?

The manufacturing process of the BOV system differs significantly from traditional aerosol filling:

First phase - Insertion: The valve with the welded bag is inserted into the metal container.

Second phase - Pressurization: Compressed gas (air or nitrogen) is introduced between the bag and the container at pressures of 3-4 bares, subsequently sealing by crimping.

Third phase - Product filling: The content is injected through the stem directly into the bag using pressure, without coming into contact with the propellant.

Final phase: The actuator is placed, completing the system ready for use.

"Contrary to what happens with traditional aerosol filling, in the BOV system, pressurization is performed first, followed by product loading" - Perfumería Moderna

Technical advantages of the BOV system

Total product-propellant separation: Complete separation avoids unwanted chemical reactions and maintains the stability of the original formulation.

360° dispensing: The system allows use in any position, even inverted, without affecting spray quality.

99% evacuation: AILE confirms that BOV products are emptied up to 99%, minimizing waste.

Extended shelf life: By eliminating oxidation and contamination, products maintain their properties for longer, reducing the need for preservatives.

Controlled spraying: The system produces a more uniform and constant spray without splashing or dripping.

What are the applications of BOV?

The versatility of the BOV system makes it suitable for multiple industrial sectors:

• Cosmetic and personal care sector: Deodorants, body lotions, shaving gels, facial mists, and sunscreen products.
• Food industry: Spray oils, dressings, mousses, creams, and products requiring preservation without preservatives.
• Pharmaceutical sector: Saline solutions, burn gels, and sterile products requiring maximum purity.
• Household products: Air fresheners, glass cleaners, and specialized cleaning products.
• Industrial applications: Specialized lubricants, maintenance products, and technical applications.

Economic considerations of the BOV system

Although the BOV system offers superior technical advantages, it presents specific economic considerations. PROERSA indicates that the BOV valve is 4-5 times more expensive than a traditional valve, with differences of approximately 0,20€ per unit compared to standard nitrogen systems.

For thermal water projects, the minimum orders required are 50.000 containers for 300ml formats, due to the limitations of manufacturers specialized in these specific sizes.

"The main factor limiting the expansion of BOV technology is its cost. This makes it a premium product that high-end brands can afford" - PROERSA

Sustainability and environmental aspects

Eco-friendly propellants: The use of compressed air or nitrogen eliminates the need for petrochemical gases, significantly reducing the carbon footprint.

Reduction of VOCs: The BOV system allows for formulating products with low volatile organic compound content, complying with the strictest environmental regulations.

Complete recyclability: The aluminum containers used are 100% recyclable, contributing to the circular economy.

Waste minimization: The 99% product evacuation drastically reduces waste compared to traditional aerosols.

Technical limitations of BOV

The BOV system is not suitable for all products. Some formulations specifically require the properties of traditional propellants:

• Dry shampoos: They need the propellant power of gas to effectively deliver dry particles to the hair.
• Voluminous foams: They require gas to create the characteristic foamy texture of the product.
• High viscosity products: Although BOV handles viscous products, there is a limit that allows passage through the valve stem.

Future trends in the BOV market

The global BOV aerosol market is experiencing sustained growth. Verified Market Reports projects that the BOV market will reach 2,85 billion dollars in 2033, with a compound annual growth rate of 6,5%.

Key trends include the development of biodegradable materials for bags, expansion into new sectors such as food and beverages, and the implementation of smart dispensing technologies that optimize product dosing.