Market	Characterization	of	the	U.S.	Aerosols	

Industry	

P REPARED FOR :

       Stratospheric	Protection	Division		

Office	of	Air	and	Radiation		

U.S.	Environmental	Protection	Agency		

Washington,	D.C.	20460		

P REPARED B Y :

ICF	International		

1725	Eye	Street,	NW		

Washington,	DC	20006		

M A Y 2014
Market	Characterization	of	the	U.S.	Aerosols	

Industry	

Table of Contents

1. Introduction ..........................................................................................................................................2

2. Market Characterization ....................................................................................................................... 2

2.1. Overview of Aerosol Products ...................................................................................................... 3

2.2. Consumer Aerosols....................................................................................................................... 4

2.3. Technical Aerosols ........................................................................................................................ 7

2.4. Medical Aerosols........................................................................................................................... 9

3. Sector Background.............................................................................................................................. 10

3.1. Aerosol Propellants..................................................................................................................... 12

3.2. Aerosol Solvents.......................................................................................................................... 13

4. Climate‐Friendly Alternatives ............................................................................................................. 14

5. References ..........................................................................................................................................16

  
2

1. Introduction			

Aerosols contain propellants emitted during use. Aerosols use liquefied or compressed gas to propel

active ingredients in liquid, paste, or powder form and many also contain a solvent. Historically, a variety

of propellants and solvents have been available to formulators. Hydrocarbons (HCs) (e.g., propane,

isobutane, blends) and compressed gases (e.g., CO2, N2O, compressed air) have long been used. Prior to

1978, CFCs were predominantly used by the aerosol industry. CFCs were excellent propellants because

of their ability to produce a fine spray; they are non‐flammable, could be stored under low pressure, and

do not react with other ingredients. In 1973 chemists Sherwood Rowland and Mario Molina began

studying effects of CFCs on the earth’s atmosphere. They discovered that CFCs were stable enough to

migrate to the stratosphere and that the chlorine atoms contained in these molecules could break down

large amounts of ozone in the stratosphere. In 1975, a major manufacturer of household aerosol

products eliminated CFC propellants over concerns for depletion of the Earth’s ozone layer. In 1978, the

United States banned CFC propellants.

Many consumer products previously using CFCs were reformulated or replaced with a variety of

alternatives, including not in kind substitutes, such as pump sprays or solid and roll‐on deodorants.

Aerosol propellant alternatives include hydrochlorofluorocarbons (HCFCs) as well as the re‐uptake of

HCs, compressed gases, and oxygenated organic compounds. However, HCFCs are controlled substances

under the Montreal Protocol on Substances that Deplete the Ozone Layer, and subject to regulation

under the CAA including a phaseout of production and import. Sale and distribution of aerosols using

HCFCs was banned in 1994 with few exceptions.  

HCFC propellants were replaced with a range of alternatives including hydrofluorocarbons (HFCs) (e.g.,

HFC‐134a, HFC‐152a) HCs, compressed gases, and not‐in‐kind (NIK) alternatives. CFC and HCFC solvents

were replaced by HFC‐4310mee, HFC‐365mfc, HFC‐245fa, HCs, oxygenated organic compounds, and

hydrofluoroethers (HFEs). Other low‐GWP fluorinated compounds are in use or under development,

including hydrofluoroolefins (HFOs). HFO‐1234ze is being used in the aerosol industry.  

The purpose of this paper is to characterize the U.S. aerosol sector in terms of market size, key market

players, historical and current propellant and solvent use, and the availability of alternative propellants

and solvents.

2. Market Characterization

The U.S. aerosol industry is characterized by many product types and applications involving multiple

companies and markets. 1 It also can be characterized as a North American market rather than a global

market.  Finished products are not complex to manufacture and require little labor; therefore, domestic

                                                            

1 NAICS codes were used to the extent possible to determine economic data about the aerosol market; however, the NAICS

codes also include a large majority of products which are not aerosols. More detailed NAICS codes (8 to 10 digits) were

researched when available.
3

production is more affordable than shipping products from overseas (Falcon Safety 2007). Additionally,

the U.S. aerosol market is subject to VOC regulations, and as a result, the United States uses larger

volumes of HFCs in aerosol propellants relative to other markets in the world.  

According to the 2011 Aerosol Pressurized Products Survey conducted by the Consumer Specialty

Products Association (CSPA), approximately 3.8 billion units were filled in 2011 by U.S. producers, which

was 36 million units higher than the total units filled in 2010 (CSPA 2012). Approximately $15 billion in

annual revenue is generated from the sale of aerosol products nationwide. As shown in Figure 1,

household and personal care products constitute about half of the aerosol units filled in 2011.

Figure 1: Number of Aerosol Units Filled in 2011 in the United Statesa

a Source: CSPA (2012). 

The remainder of this section is organized into the three aerosol product categories—consumer,

technical, and medical. Information was gathered using a variety of sources, including, market profiles,

historical research, and information provided by the aerosol and chemical manufacturing industries.

2.1. 		Overview of Aerosol Products

The U.S. aerosol industry is comprised of the following three product categories:

 Consumer Aerosols – this grouping consists of a wide variety of products using aerosol

packaging for personal and household use. Examples include personal care products such as  

cosmetics, hairspray, body sprays, and deodorants are covered by this category along with a

wide variety of other products such as tire inflators and other automotive products (e.g., auto

lubricants, brake cleaners); noise horns and safety horns; animal repellants;   

spray adhesive with various applications; household and office cleaning products; hand‐held

spray cans; eyeglass and keyboard dusters; consumer freeze sprays (e.g., chewing gum or

excrement removal); room fresheners; food dispensing products; and novelty aerosols (e.g.,

artificial snow, plastic string, noise makers, and cork poppers).

 Technical Aerosols – this grouping consists of highly specialized products for sale and use solely

in commercial and industrial applications that are not for normal day‐to‐day use. Technical

aerosols include (but are not limited to) those products exempted from the non‐essential

Insect Sprays

6%

Paints and

Finishes

11%

Household

Products

28%

Personal Care

Products

27%

Food

13% Automotive

13%

Animal Products

<1%

Miscellaneous

2%
4

products bans under EPA regulations at 40 CFR Part 82, Subpart C.2  Products include industrial

cleaners (e.g., electronic contact cleaners, flux removers, degreasers); pesticides (e.g., certain

wasp and hornet sprays, aircraft insecticides), mold release agents, and certain dusters (e.g., for

photographic negatives, semiconductor chip manufacture, specimens for observation under

electron microscope); and spinnerette lubricant/cleaning sprays.  Other miscellaneous products

such as industrial spray paints and document preservation sprays are also considered in this

category.   

 Medical Aerosols – this grouping consists of products that are used for healing or medicinal

purposes. These include, but are not limited to, products regulated by the U.S. Food and Drug

Administration. Medical aerosols include metered dose inhalers for the treatment of asthma

and chronic obstructive pulmonary disease, calamine spray, anti‐fungals, wart treatments,

wound care sprays, freeze or coolant spray for pain relief, spray‐on “liquid” bandages, and

products for removing bandage adhesives. Although aerosol propellants are used in metered

dose inhalers (MDIs), MDIs are not explored in this market characterization.3

   

Some end‐uses may be represented in more than one of the above categories. For example, insect

sprayers have parallel lines of products with similar end‐uses in both commercial and consumer

applications, one to be used by line workers around electrical lines (i.e., a technical aerosol), and

another as household insect repellant (i.e., a consumer aerosol). Additionally, freeze sprays can be a

consumer aerosol (e.g., food freeze sprays, animal waste sprays) or a medical aerosol (e.g., wart

removers, numbing sprays).   

According to the CSPA, around 400 aerosol product‐related companies exist in the United States 12.5%

of which are in California (AboutAerosols 2013). These companies include those producing aerosol

components (e.g., valves, cans, propellants, and other ingredients), formulating and marketing products

in aerosol form, or filling aerosol products (AboutAerosols 2013). An estimated 138 companies have

facilities with filling lines in the United States (CSPA 2012).

   

2.2. 		Consumer Aerosols

Demand for consumer aerosols in the United States is most concentrated within household products,

which continue to rank as the highest production product category, reporting a 2.4% increase from 2010

to 2011 (CSPA 2012). This trend is also true globally; about 90% of the 6.8 billion metal aerosol cans sold

worldwide in 2011 are in the beauty and household markets with 27% of sales for household care and

69% of sales for applications in deodorant sprays, insecticides, air fresheners and styling agents (Downey

                                                            

2 Under the non‐essential products ban, all aerosol products, pressurized dispensers and foam products containing, or

manufactured with, CFCs and HCFCs ‐‐ except those specifically exempted by the regulations and those that are listed as

essential medical devices by the Food and Drug Administration, at 21 CFR 2.125(e) ‐‐ are banned from sale and distribution in

interstate commerce in the U.S..

3 CFC‐based propellants have historically been used in MDIs for inhalation therapy.  A gradual shift toward the use of HFC

propellants, including HFC‐134a and HFC‐227ea, began in the early 1990s.  Dry powder inhalers (DPIs) are an alternative to

MDIs; these delivery systems do not require a propellant and have been in use for more than 20 years.  Although DPI use is on

the rise and accounts for about one‐third of all inhaled medication, it is recognized that both DPIs and HFC MDIs play important

roles in inhalation therapy.  
5

2012). A number of consumer aerosol products meet niche demands, with overall volume being very

small relative to other consumer aerosol products (e.g., boat safety horns). Such products may be

purchased but not used for a long period of time (e.g., years), as they may be stored for emergency uses

only.  Some of the larger end‐uses of consumer aerosols are described with further detail in Table 1.    

Table 1. Market Characterization for Consumer Aerosols

Product Major Producers Key Market Information 

Propellants Solvents 

Historical Current 

(2014) Historical Current (2014) 

Air 

Fresheners 

 Henkel AG & Co. 

 KGaA 

 Procter & Gamble 

 Reckitt Benckiser Inc. 

 SC Johnson & Son 

 U.S. market grew by 3.4% 

in 2011 (Research and 

Markets 2012a) 

 Value of $1.8 million with 

total revenue of $770 million 

 Pump/aerosol air fresheners 

account for 44% of market’s 

total value in 2011 

(Research and Markets 

2012a) 

U  HCs 

 HFC152a 

 not-inkind 

 CGs 

U U 

Deodorants/ 

Antiperspirants 

 Procter & Gamble 

 Unilever 

 Colgate Palmolive 

 Dial Corporation 

 Lever Brothers 

 Revlon 

 Church and Dwight 

 Spray deodorants account 

for 14% of North America’s 

deodorant sales (Downey 

2012). 

 US deodorants market 

generated total revenues of 

$2.5 billion in 2009, at a 

compound annual growth of 

4.8% from 2005-2009 

(Research and Markets 

2012b)

U  HCs 

 HFC152a 

 not-inkind 

U U 

Household 

Cleaners4

 Procter & Gamble 

 Chase Products Co. 

 The Clorox Company 

 SC Johnson & Son 

 Church and Dwight 

 Reckitt Benckiser Inc. 

 Household products 

continue to rank as the 

highest production product 

per unit of aerosol cans 

filled, reporting a 2.4% 

increase from 2010 to 2011 

(CSPA 2012) 

U  HCs 

 CGs 

 Dimeth

yl ether 

U U 

Hair Spray  Alberto-Culver 

Company 

 Kao Brands 

 Procter & Gamble 

 Unilever 

 Approximately 303 million 

aluminum and steel 

containers of hair spray 

were filled in 2011 as 

reported by 97 U.S. 

company facilities (CSPA 

2013) 

 In 1999, HFC-152a was 

used in approximately 31.7 

million hair sprays based on 

a review of 62 products (ICF 

U  HCs 

 HFC152a 

U U 

                                                            

4

 This category in the CSPA survey contains a large number of products, including room deodorants and disinfectants, cleaners for 

glass, oven, rug, fabric, wall, tile etc., laundry products, waxes and polishes, and other household products (e.g., shoe polishes, 

dyes, leather dressings, fuels, drain openers, antistatic sprays, caulking and sealing compounds). 
6

Product Major Producers Key Market Information 

Propellants Solvents 

Historical Current 

(2014) Historical Current (2014) 

1999) 

 Pump sprays account for 

44% of the market (HHS 

2013) 

Tire Inflators  ITW Global Brands 

 Valvoline, Co. 

 Radiator Specialty 

Company 

 Warren Distribution, 

Inc. 

 Hutchinson Tires 

U  HCFC22 

 HCs 

 Dimeth

yl ether 

 HFC134a 

U U 

Brake 

Cleaners 

 Sprayaway, Inc. 

 Trak Auto Corporation 

U U 

 CO2

Methyl 

Chlorofor

m 

 Perchlo

roethylen

e 

Safety Horns  Falcon Safety  According to Falcon Safety, 

signal horns do not use 

HFC-152a because of 

safety concerns; 

hydrocarbons are safer for 

these applications than 

HFC-152a. 

 One manufacturer makes 

about 100,000 horns per 

year and 100,000 refills a 

year (Falcon Safety 2007) 

U  HCs 

 HFC134a 

 HFO1234ze 

U U 

Dusters  Falcon Safety 

 Sprayaway 

 The duster spray market 

has increased steadily with 

the advent of digitalization in 

the U.S., but is now a 

mature market (Falcon 

Safety 2007)

 One manufacturer makes 

500,000 – 1 million cans (10 

ounces) per year charged 

with HFC-134a and 11 

million cans per year 

charged with HFC-152a 

(Falcon Safety 2007)

 CSPA estimated that in 

2008, approximately 1,300 

metric tons (MT) of HFC134a (14%) and 8,300 MT 

of HFC-152a (86%) were 

used as propellants in 

dusters (CSPA 2008).

 HCFC22  HFC134a 

 HFC152a 

 HCs 

 Dimeth

yl ether 

Not 

applicable 

Not 

applicable 
7

U indicates that information is not readily available. 

2.3. 		Technical Aerosols

Technical aerosols are pressurized products used to clean, maintain, fix, test, manufacture, disinfect, or

apply lubricant and mold release agents to various equipment, as well as in a number of industrial

processes (TEAP 2005). Many of the products within the technical aerosols category, including aircraft

maintenance products, wasp and hornet sprays, and spinnerette lubricant sprays, are highly specialized

products that fill niche market demands.  

Table 1 presents a summary of the major producers, historically used propellants and solvents, and

currently used propellants and solvents for commonly‐used technical aerosols.  

Table 1: Market Characterization for Technical Aerosols

Product Major 

Producers 

Key Market 

Information 

Propellants Solvents 

Historical Current 

(2014) Historical Current (2014) 

Degreasers  CRC 

Industries 

 ITW, Inc. 

 Micro-Care 

 MillerStephenson 

 Price-Driscoll 

Corporation 

 SprayOn, Inc. 

 Zep 

Commercial 

U  CFC11/CFC-12 

mixture 

 Methyl 

chloroform 

 HFC-134a 

 HFC-152a 

 HCs 

 Compress

ed Gases 

 CFC-11 

 CFC-113 

 HCFC225ca/cb 

 Chlorinated 

solvents 

 trans-dichloroethylene 

 HFC-43-10mee 

 HFC-365mfc 

 HFC-245fa 

 HFE-7100 

 HFE-7200 

 N-propyl bromide 

 Dimethyl ether 

 Petroleum 

distillates 

 Oxygenated 

organic compounds 

Aircraft 

Maintenanc

e Products 

 3M Company 

 GLI Aviation 

Products 

 ITW, Inc. 

 LHB 

Industries 

 Nonflammability is a 

critical 

characteristic 

 HCFC-22 

 CO2

 CO2

 not-in-kind 

 HCFC141b  HFE-7100 and 

blends 

 HFC-43-10mee 

 trans-dichloroethylene 

 not-in-kind 

 Petroleum 

distillates 

 Oxygenated 

organic compounds 

Wasp and 

Hornet 

Sprays5

 Amrep, Inc. 

 LTC Products 

U  HCFC-22 

 CO2

 HCs 

 CO2

 Nitrogen 

 Methyl 

Chloroform 

 Petroleum 

distillates 

                                                            

5

 Wasp and hornet sprays are often used by industrial users, such as public utility workers, for use on high-tension power lines. 
8

Product Major 

Producers 

Key Market 

Information 

Propellants Solvents 

Historical Current 

(2014) Historical Current (2014) 

Spinnerette 

Lubricant 

Sprays6

 ALFA 

 G. D. 

Silicones 

Tania 

International 

 ITW, Inc. 

 Price-Driscoll 

Corporation 

 Specialty 

product with 

only four 

manufacturers 

– small 

percentage of 

the product line 

 In 1998, one 

company was 

selling 20,000 

cans per year 

and another 

manufactured 

100,000 cans 

per year (ICF 

1998). 

 CFC-12 

 HCFC-22 

 HFC-134a  CFC-114  n-propyl bromide 

 Dimethyl ether 

 Methyl siloxanes 

Brake 

Cleaners 

 Sprayaway, 

Inc. 

 Trak Auto 

Corporation 

U U  CO2  Methyl 

Chloroform 

 Perchloroethylene 

Flux 

Removers7

 CRC 

Industries 

 ITW, Inc. 

 Micro-Care 

 MillerStephenson 

 Petroferm, 

Inc. 

U  CFC-12  HFC-134a  CFC-11 

 CFC-113 

 Methyl 

chloroform 

 HCFC141b 

 HCFC225ca/cb 

 HFC-4310mee 

 HFC-245fa 

 trans-dichloroethylene 

 Chlorinated 

solvents 

 n-propyl bromide 

 Oxygenated 

organic solvents 

Document 

Preservatio

n Sprays8

 Preservation 

Technologies 

U  CFC-12 

 HCFC-22 

 CO2

 HCs 

 CFC-113 

 HCFC141b 

 Petroleum 

distillates 

Dusters9  CRC 

Industries 

 Falcon Safety 

 MG 

Chemicals 

 SprayOn, Inc. 

 U  HFC-134a Not 

applicable 

Not applicable 

Lubricant 

Sprays10

 Amrep, Inc. 

 Price-Driscoll 

Corporation 

U U  HCs 

 CO2

 HCFC141b 

U 

                                                            

6

 Spinnerettes are used for the production of synthetic fibers (e.g., nylon). They are steel structures with many tiny holes through 

which melted resin is passed to form a spun fiber. Lubricants are applied to the spinnerette to facilitate spinning and prevent the 

fibers from sticking to the accumulated resin on the block (ICF 1998). 7 Flux removers are used to clean excess flux and solder residue from circuit boards and electrical components. 8 Document preservation sprays are deacidification sprays that neutralize the acid in paper that causes paper to weaken and

become brittle over time. 9 Dusters that fall under the technical aerosols category include more specialized dusters used for applications such as

photographic negatives, semiconductor chip manufacture, and specimens for observation under electron microscope. 10 Lubricants reduce friction, heat, and wear when applied to the surfaces between moving parts. They are mainly used to

repair and maintain electronic equipment and reduce friction between mechanical parts. Cleaner lubricants remove dirt and
9

Product Major 

Producers 

Key Market 

Information 

Propellants Solvents 

Historical Current 

(2014) Historical Current (2014) 

 Nitrogen 

Mold 

Release 

Agents 

 Amrep, Inc. 

 Price-Driscoll 

Corporation 

 Sprayon 

U  CFC-12 

 HCs 

 CO2

 HCs 

 CO2

 HFC-134a 

 not-in-kind 

 CFC-11 

 CFC-113 

 HCFC141b 

 Methylene chloride 

 Perchloroethylene 

 HCs 

 Oxygenated 

organic solvents 

U indicates that information is not readily available. Sources: ICF (1998); CSPA (2008); HHS (2013). 

2.4. 		Medical Aerosols

Medical aerosols are a group of aerosol products used to offer pain and itch relief, remove warts, and

apply bandages and antiseptic.11 Limited information is available regarding the market size for medical

aerosols, including liquid bandages, freeze sprays (i.e., wart removers), calamine sprays, anti‐fungal

sprays, and bandage adhesive and remover.  There are not‐in‐kind alternatives currently available for

each of these medical aerosols, including lotions and pump sprays. Table 2 provides a summary of the

major producers and gases historically and currently used as propellants and solvents in medical

aerosols, as available. Key Market Information

Table 2: Market Characterization Summary for Medical Aerosols

Product Major Producers Key Market 

Information 

Propellants Solvents 

Historical Current Historical Current 

Liquid 

Bandages 

 Amerisource 

Bergen 

Corporation 

 Johnson & 

Johnson 

Consumer 

Companies, Inc. 

 NMS 

Technologies 

 Prestige 

Brands, Inc. 

U  NA  HCs 

 not-in-kind 

U  Oxygenated 

organic 

solvents 

Freeze 

Sprays12

 Merck & Co., 

Inc. 

 Prestige 

Brands, Inc. 

U  CFCs  HCs 

 Liquefied 

petroleum 

gas 

 Dimethyl 

ether 

 not-in-kind 

U  Oxygenated 

organic 

solvents 

                                                            

dust while simultaneously applying a protective layer of grease on a given surface (ICF 1998).  Examples of applications include

aircraft maintenance and electrical, electronic or photographic equipment. 11 Although aerosol propellants are used in metered dose inhalers (MDIs), MDIs are not explored in this market

characterization.

12 Freeze sprays include both wart removing freeze sprays and topical coolant sprays for pain alleviation. 
10

Product Major Producers Key Market 

Information 

Propellants Solvents 

Historical Current Historical Current 

Calamine 

Spray 

 Johnson & 

Johnson 

Consumer 

Companies, Inc. 

U  CFC-11/12 

mixture 

 CFC-12 

 HCFC-22 

 HCs 

 Dimethyl 

ether 

 not-in-kind 

 Methylene 

chloride 

 HCFC-141b 

 Oxygenated 

organic 

solvents 

Anti-fungal 

Sprays 

 MSD Consumer 

Care, Inc. 

U  CFC-11/12 

mixture 

 CFC-12 

 HCFC-22 

 HCs 

 Dimethyl 

ether 

 not-in-kind 

 Methylene 

chloride 

 HCFC-141b 

 Oxygenated 

organic 

solvents 

Bandage 

Adhesive 

and 

Remover 

 ARI 

 Medline 

Industries, Inc. 

 Pac-Kit Safety 

Equipment 

U  CFCs  HCs 

 DME 

 not-in-kind 

 CFC-113  Oxygenated 

organic 

solvents 

Sources: HHS (2013); Good Guide (2013); EPA (2013a); Proctor & Gamble (1973); EPA (1990) 

U indicates that information is unavailable. 

3. Sector Background

Historically, a variety of propellants and solvents have been available to aerosol formulators. While

hydrocarbons (HCs) (e.g., propane, isobutane, blends) and compressed gases (CGs) (e.g., CO2, N2O,

compressed air) have always had a market presence, before 1978, CFCs and other ODS were the

predominate propellants and solvents used by the aerosol industry because of their excellent mixing,

solvating, and dispersing properties. CFC‐12 was the most popular propellant and other CFCs (e.g., CFC‐

11 and ‐113) and methyl chloroform were often used as solvents in aerosols. CFCs were excellent as

propellants because of their ability to produce a fine spray; they were non‐flammable, could be stored

under low pressure, did not react with other ingredients, and were safe to use. CFCs were also excellent

solvents because they were effective at dissolving active ingredients used in aerosol products.  

In response to the 1978 ban, many consumer products previously using CFCs were reformulated

successfully or replaced with a variety of alternatives, including not‐in‐kind alternatives, such as pump

sprays or solid and roll‐on deodorants. The market trended toward the use of these not‐in‐kind

products, which were found to be less‐expensive to manufacture than the aerosol based products.  

Aerosol propellant alternatives to CFC‐based aerosols also emerged into the market including HCFCs—

notably HCFC‐22 as a propellant, and HCFC‐141b and HCFC‐225ca/cb as solvents—in addition to HCs,

compressed gases, and oxygenated organic compounds (e.g., alcohols, ketones, esters).   

Despite the prohibition of the manufacture of CFC‐based aerosol propellant products in 1978, other

uses of CFCs in aerosols (such as solvents, active ingredients, or sole ingredients) and certain   uses of

CFC‐based aerosol propellants were exempted from the ban given the lack of alternatives available at

the time. Section 610 of the 1990 Clean Air Act Amendments established the nonessential products bans

which addressed  most of the remaining uses of CFCs and HCFCs in aerosols and pressurized

dispensers13The Nonessential Product Bans in 1993 and 1994 prohibited the sale, distribution, or offer

                                                            

13 Products still using CFCs at the time included plastic party streamers, noise horns (e.g., marine safety noise horns, sporting
11

for sale or distribution of all CFC‐containing and HCFC‐containing aerosols unless specifically accepted.

In establishing these bans, the EPA considered the purpose or intended use of the product, the

technological availability of alternatives, safety, health, and other relevant factors14.   

In the 1990s, HCFC propellants began to be replaced with high‐GWP HFCs—including HFC‐134a—as well

as a variety of lower or no global warming potential alternatives, such as HCs, compressed gases, not‐in‐

kind alternatives, and HFC‐152a. Similarly, HCFC solvents also began to be replaced by HFC‐4310mee,

HFC‐365mfc, HFC‐245fa, HCs, oxygenated organic compounds, and hydrofluoroethers (HFEs). The

industry overcame technical hurdles with HFCs and HFEs by blending these compounds with substances

such as trans‐1,2‐dichloroethylene to increase solvency. Trans‐1,2‐dichloroethylene, commonly referred

to as “trans,” is an aggressive solvent. Because of this characteristic, and because of its flammability,

trans is usually combined with other solvents, such as HFCs and HFEs, to form effective azeotropes that

are less flammable and less aggressive on precision metal and electronics parts.   

Additionally, the U.S. aerosol market is using a larger volume of HFCs in aerosol products relative to

aerosol markets globally due to continuously evolving state and federal regulations for volatile organic

compounds (VOC) that require manufacturers to limit the amount of VOC (e.g., HCs) in their

formulations for various locations of the country. HFCs, such as HFC‐152a, are exempt from the

definition of VOC in regulations under the Clean Air Act addressing the development of State

Implementation Plans (SIPs) to attain and maintain the national ambient air quality standards (40 CFR

51.100(s)), and therefore, can be a suitable alternative to VOC in states (or municipalities) with VOC

restrictions.

VOC regulations often drive propellant and solvent formulation choices in aerosol products. States that

regulate the VOC content in consumer products include California, the Ozone Transport Commission or

“OTC” states (Virginia to Maine), and the Lake Michigan Air Directors Consortium, or “LADCO” states

(Illinois, Indiana, Michigan, Ohio, and Wisconsin) (Geer 2011; ISSA 2012; Beaver 2011). Individual states

such as Texas and Georgia and counties within certain states (e.g., Atlanta metro area and Phoenix) also

have VOC regulations (Beaver 2011). VOC regulations can affect the entire aerosol formulation—the

solvent system must match the propellant formulation, and if one component changes, the entire

formulation is affected.  

                                                            

event noise horns,  personal safety noise horns), and cleaning fluids for noncommercial electronic and photographic equipment

(e.g., solvent wipes, keyboard dusters, flux removers, and  tape and computer disk head cleaners).

14 The EPA exempted the following products from the nonessential product bans: Aircraft pesticides; Medical devices listed in

21 CFR 2.125(e); Lubricants, coatings, or cleaning fluids for aircraft maintenance containing CFCs or HCFCs as solvents;

Lubricants, coatings, or cleaning fluids for electrical, electronic or photographic equipment containing CFCs or HCFCs as

solvents; Mold release agents containing CFCs and HCFCs as solvents and mold release agents containing HCFC‐22 as a

propellant; Spinnerette lubricant/cleaning sprays containing CFCs or HCFCs as solvents and/or propellants; Document

preservation sprays containing CFCs and HCFCs as solvents; Document preservation sprays containing CFCS or HCFCs as

propellants for use on thick books with coated or dense paper, and tightly bound documents, only; Wasp and hornet sprays

containing CFCs or HCFCs for use near high‐tension power lines only; Lubricants for pharmaceutical and tablet manufacture;

Gauze bandage adhesives and adhesive removers; and Red pepper bear repellent sprays which contain CFC‐113 as the solvent

but which contain no other CFCs.
12

Different products have different VOC limits, which can vary based on local regulations.  For example the

VOC limit for hairspray cannot exceed 80 percent (on a weight percent basis) according to EPA

regulation. However, in California and other states with VOC regulations, the limit cannot exceed 55

percent; for aerosol deodorants, the EPA has a 20 percent VOC limit, but California and other states only

allow a 0‐10 percent limit (ISSA 2012).  

Although on occasion differing formulations have been designed for the same product in different

locales, it is often not practical for an aerosol manufacturer to change the aerosol formulation of the

same product to address varying VOC regulations (i.e., no‐VOC, low‐VOC, and high‐VOC formulations).  

Therefore, to comply with VOC regulations in one state or area (e.g., if HFC‐152a is the only option in

California), a manufacturer may use the same substitute in all formulations of one product across the

U.S., which increases the use of HFCs nationally for some products.  

3.1.		Aerosol Propellants

The U.S. aerosol industry has already made significant progress in adopting a variety of propellants and

not‐in‐kind alternatives to ODS (i.e., CFCs, HCFCs); however, high‐GWP HFCs continue to occupy a

significant portion of aerosol products on the market, particularly in personal consumer products. Table

4 illustrates a sample of household aerosol products containing propellants queried from the U.S.

Department of Health and Human Services Household Product Database (HHS, 2013). Based on this

sampling, personal care (which are also the largest continued user of HFC propellants) and household

and home office products make up the majority of aerosol products currently manufactured.  

Table 4: Sample of Propellants in Aerosol Products from the U.S. HHS Household Products Databasea

Category (Total Sample Size) Propellant Type Percentage of Products in Sample by Propellant Type 

Arts and Crafts (74) 

HFC-134a 1% 

Hydrocarbons 96% 

Dimethyl ether 3% 

Auto Products (130) 

HFC-134a 12% 

HFC-152a 3% 

Hydrocarbons 72% 

Carbon dioxide 2% 

Dimethyl ether 11% 

Home Maintenance (154) 

HFC-134a 6% 

Hydrocarbons 76% 

Dimethyl ether 16% 

Household and Home Office 

(364) 

HFC-134a 1% 

HFC-152a 3% 

Hydrocarbons 86% 

Compressed Gas 6% 

Dimethyl ether 3% 

Personal Care (285) 

HFC-134a <1% 

HFC-152a 35% 

Dimethyl ether 18% 

Hydrocarbons 46% 

Pesticides (92) HFC-152a 1% 

Hydrocarbons 99% 

Pet Care (16) Hydrocarbons 70% 

Dimethyl ether 30% 
13

a Source: HHS (2013). 

Note: A query was performed in March 2013 on the aerosol products listed in the U.S. HHS Household Products Database to provide the 

sampling shown in this table. Products were identified through searches of products containing known aerosol propellants. This table and 

the U.S. HHS Household Products Database does not provide a comprehensive compilation of all products on the market that utilize aerosol 

propellants. Rather, this sampling is intended to demonstrate the various aerosol propellants used in 2013 among categories tracked in this 

database. Different variations of the same product (i.e. air fresheners with different scents or spray paints of different colors) are counted as 

separate products. 

In the early to mid‐1990s, ODS propellants included CFC‐12, CFC‐114, HCFC‐22, and HCFC‐142b, with

minimal use levels prior to the 1978 ban, because their market presence was in exempted products

only. HCFC‐22 was the most widely used HCFC propellant in the 1990s with the transition from CFC‐12

to HCFC‐22 taking place during 1990 and 1991. Beginning in the 1990s the aerosol industry also became

far more dependent upon HFCs with the introduction of VOC regulations in the 1990s, despite the

widespread use of HCs‐‐known VOCs‐‐in aerosol products.   

The Consumer Specialty Products Association (CSPA) estimated that in 2008, the majority of products

using HFC‐152a were consumer products (e.g., hairsprays, dusters, deodorant body sprays,

antiperspirants, and deodorants) with total use equal to 21,417 MT, and the majority of products using

HFC‐134a were technical products (e.g., tire sealant/inflators and degreasers) with total use of 3,242 MT

(CSPA 2008).

3.2. 		Aerosol Solvents				

Table 5 illustrates a sample of household aerosol products containing solvents queried from the U.S.

Department of Health and Human Services Household Product Database (HHS, 2013).  As shown, auto

products and household and home office products make up the majority of aerosol products using

aerosol solvents currently manufactured.

Table 5: Sample of Solvents in Aerosol Products from the U.S. HHS Household Products Databasea

Category (Total Sample Size) Solvent Type Percentage of Product in Sample by 

Solvent Type 

Arts and Crafts (111) 

Hydrocarbons 47% 

Oxygenated Organic Solvents 50% 

Chlorinated Organic Solvents 4% 

Auto Products (163) 

Hydrocarbons 37% 

Oxygenated Organic Solvents 45% 

Chlorinated Organic Solvents 17% 

Home Maintenance (72) 

Hydrocarbons 44% 

Oxygenated Organic Solvents 35% 

Chlorinated Organic Solvents 19% 

Household and Home Office 

(97) 

Hydrocarbons 71% 

Oxygenated Organic Solvents 24% 

Chlorinated Organic Solvents 5% 

Personal Care (3) Hydrocarbons 100% 

Pesticides (19) Hydrocarbons 100% 

Pet Care (2) Hydrocarbons 100% 

a Source: HHS (2013). 

Note: A query was performed in March 2013 on the aerosol products listed in the U.S. HHS Household Products Database to provide the 

sampling shown in this table. Products were identified through searches of products containing known aerosol solvents. This table and the 

U.S. HHS Household Products Database does not provide a comprehensive compilation of all products on the market that utilize aerosol 

solvents. Rather, this sampling is intended to demonstrate the various aerosol solvents used in 2013 among categories tracked in this 
14

database. Different variations of the same product (i.e. air fresheners with different scents or spray paints of different colors) are counted as 

separate products. 

Aerosol solvent applications historically used CFC‐11, CFC‐113, methyl chloroform, and HCFC‐141b. CFC‐

11 was used in precision and general mold release agents, and exclusively as a diluent15, not as an active

ingredient in solvent applications. CFC‐113 served as both a diluent and active ingredient (i.e., in

electronics solvent cleaners and as a diluent in mold release agents and lubricants). Methyl chloroform

was more widespread in its use (i.e., as a diluent in applications such as water and oil repellants, tire

shiners, insecticides, and mold release agents and as a solvent in electric motor cleaners, spot removers,

and brake cleaners). Information on HFC use (e.g., HFC‐43‐10mee and HFC‐365mfc) in the aerosol

solvent market is not readily available; however, it is expected to be minimal (IPCC 2005).  

4. Climate‐Friendly Alternatives

A variety of alternatives are available to replace HCFC, HFC‐134a and HFC‐152a propellants and HCFCs,

HFC‐4310mee, HFC‐365mfc, and HFC‐245fa solvents used in aerosols. Many alternatives have an

established market presence because of the direct transition from CFCs and HCFCs to hydrocarbons,

oxygenated organic compounds, and not‐in‐kind alternatives. Low‐GWP fluorinated compounds are also

in use or under development, including HFOs. Table 6 below summarizes the current use in the U.S. and

the status under SNAP.

Table 6: Overview of Climate‐friendly Alternatives  

Alternative Overview 

Aerosol Propellants 

C3-C6 Hydrocarbons (propane, nbutane, isobutane) 

 Acceptable under SNAP 

 Widely used in consumer, technical, and medical aerosols in the U.S. 

Dimethyl Ether  Acceptable under SNAP 

 Widely used in consumer, technical, and medical aerosols in the U.S. 

Not-in-kind devices  Acceptable under SNAP 

 Widely used alternative to aerosolized products in consumer, technical, 

and medical aerosols 

Compressed Gases (carbon dioxide, 

air, nitrogen, nitrous oxide) 

 Acceptable under SNAP 

 Widely used in consumer, technical, and medical aerosols in the U.S. 

HFO-1234ze(E)  Acceptable under SNAP 

 Available in the U.S. market as of 2012 

Aerosol Solvents

C5-C20 Hydrocarbons (pentane, 

hexane, heptane) 

 Acceptable under SNAP 

 Widely used in consumer, technical, and medical aerosols in the U.S. 

HFE-7000, HFE-7100, HFE-7200, HFE347pcf2 

 Acceptable under SNAP 

 Widely used in the U.S. market (HFE-347pcf2 still emerging in U.S. 

market) in technical aerosols 

SolsticeTM-1233zd(E) (also known as 

trans-1-chloro-3,3,3-trifluoroprop-1-ene) 

 Acceptable under SNAP 

 Available in the U.S. market as of 2013 

Oxygenated Organic Compounds 

(esters, ethers, alcohols, and ketones) 

 Acceptable under SNAP 

 Widely used in consumer, technical, and medical aerosols in the U.S. 

                                                            

15 A diluent is a type of solvent used to weaken the strength of a particularly aggressive solvent.
15

Many companies have already transitioned to non‐HFC propellants and solvents; however, technical,

financial, and practical barriers exist for some products that have prevented the complete transition

away from HFCs in aerosols. The European aerosol industry has adopted a Code of Practice against using

HFCs whenever feasible with only a small number of technical aerosols that do not have safe, practical,

economic or environmentally acceptable alternatives using HFCs. These include products used in

maintenance, repair, cleaning, testing, disinfecting, manufacturing, installation and other applications

where a non‐flammable formulation is required for safety reasons (EAF 2013). 

In the United States, HFCs are often the propellant of choice to address product‐related performance

and flammability when VOCs are restricted. Furthermore, replacements to HFCs are typically not drop‐in

replacements since the entire formulation must be evaluated and potentially changed. Safety

considerations are another factor for this industry when evaluating alternative formulations. In

undergoing a transition to certain replacements (e.g., flammable or more toxic compounds), workplace

environmental controls may be a large expense for a company if they do not already have them in place.

Liability insurance and associated plant safety requirements will increase if transitioning to the use of a

flammable propellant or solvent. Several additional factors must be examined when reformulating

including safety hazards (e.g., toxicity, corrosiveness, irritants, cancer/reproductive harm, flammability),

container corrosion, properties of the propellant (e.g., vapor pressure, flash point, solubility in water,

boiling point), efficacy, and cost (Geer 2011).  

Nonetheless, the use of HFCs is considered by the U.S. aerosol industry to be flat to declining, and

compared to other sectors where HFCs are used (e.g., refrigeration and air‐conditioning, foams) total

use is on a much smaller scale.  
16

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