Corrosion control & prevention

Together they’re a process, not a one-time event… Hello, everyone. Corrosion is everywhere and it’s expensive. Indeed, the estimated cost of worldwide corrosion services—testing, consulting, inhibitor/coating/laminated films for control and prevention—is expected to hit $3.48 trillion by the end of 2026. The spray packaging corrosion risk is always greater than zero and as high as […]

Do you remember or did you know?

Hello Everyone. Corrosion is an omnipresent, very complex process. Whether or not it occurs, how fast it proceeds through a spray package and the corresponding package service lifetime are all functions of: The chemical composition of a product; Its physical form inside the package; and The type of packaging material/materials, such as metals, coated metals, […]

Corrosion testing to comply with EU 2025/24

Hello everyone. Last year, EU 2025/24 Package Regulations (EUPR25) created paradigm shifts for plastic (polymer) packaging, going from single-use packaging to multiple-use reusable/refillable packaging (service life) with a high percent content of secondary polymer (waste plastic) in new packages (circularity). At a first glance, it appears this regulation has no effect on metal spray packages. […]

Corrosion by formula & package factors, Part 2

Hello everyone and Happy New Year! In this month’s column, we’ll continue on from Part 1, found in the November 2025 issue. Spray package failures occur when: Metal and plastic packages leak liquid product; An aerosol container or aerosol valve leaks propellant; A partially full package no longer sprays; The product is discolored or has […]

Corrosion by formula & package factors, Part 1

I’m sure everyone has heard about the EU 2025/24 legislation on packaging materials, made law in January of this year. This game-changing legislation will probably require a significant amount of work to either find alternate plastic (polymer) materials for packaging, and/or migrate products from plastic packaging to metal packaging. This two-part series of Corrosion Corner […]

Worst-case corrosion testing?

In this age of faster-to-market timetables, there are often pressures on formulators and engineers to accelerate the various tests needed to qualify new products and derivatives for existing products (line extensions). These pressures often tempt one to use worst-case testing to obtain quicker results. The reasoning is often that a product that passes worst-case testing […]

Toxic Relationship

Exploring the relationships between corrosion & spray packages Hello, everyone. I’ve often been asked how corrosion causes spray package failures. We’ll start by defining what is meant by a spray package failure by understanding the six types: The package leaks liquid product or propellant Valves leak propellant A partially full package no longer sprays Discolored […]

Corrosion prevention & control

Together they’re a process, not a one-time event… Hello, everyone. Corrosion is everywhere—and it’s expensive! Indeed, the estimated cost of worldwide corrosion services—testing, consulting, inhibitor/coating/laminated films for control and prevention—was a whopping $3.25 trillion in 2023. For spray packaging, the risk of corrosion is always greater than zero and as high as 62%, particularly when […]

Galvanic corrosion in aerosol packaging

Hello, everyone. Modern aerosol packages are often fabricated with two or more different metals, making galvanic corrosion possible. Galvanic corrosion is a form of localized corrosion where one metal causes the other (different) metal to corrode. Galvanic corrosion could be general corrosion, pitting corrosion or both. However, both forms of galvanic corrosion are restricted to […]

Raising temperature to accelerate corrosion, Part 2

Hello, everyone. This month I’ll complete the two-part series about the science of higher temperatures for spray package corrosion testing. Last month, we discussed the Arrhenius equation—the basis for using higher temperature to accelerate corrosion. It was demonstrated that the Arrhenius equation is usually invalid for spray package materials. Consequently, higher temperatures do not accelerate […]