Aerosols play a crucial role in the cosmetics industry, offering convenient, hygienic, and precise application for a wide range of beauty and personal care products. At Hydrokem, we specialise in contract aerosol manufacturing for cosmetics, delivering high-quality, innovative, and fully compliant formulations tailored to your brand’s needs.
Our Cosmetic Aerosol Product Range
We manufacture a variety of cosmetic aerosol products, including:
Hair Care Aerosols
- Hairsprays & Styling Mists – Providing long-lasting hold and enhanced styling for all hair types.
- Dry Shampoos – Absorbing excess oil, refreshing hair, and adding volume for a just-washed feel.
Personal Care Aerosols
- Deodorants & Antiperspirants – Formulated to keep users fresh and confident with skin-friendly ingredients.
- Shaving Foams & Gels – Delivering a smooth, protective lather for a comfortable and irritation-free shave.
Skincare & Body Care Aerosols
- Self-Tanning Sprays – Offering a streak-free, natural-looking tan with a smooth, fine mist application.
- Facial & Body Mists – Hydrating, soothing, and nutrient-infused sprays for enhanced skincare benefits.
- Sun Protection Sprays – Water-resistant SPF formulations that provide even sun protection for all skin types.
Why Choose Aerosols for Cosmetic Products?
Aerosols have become a preferred choice for many cosmetic and personal care products due to their ease of use, long shelf life, and precise application. Whether it’s for hair care, skincare, or sun protection, aerosol technology enhances product performance by:
- Ensuring even and controlled application.
- Reducing product contamination risks with sealed dispensing systems.
- Enhancing user convenience with quick-drying, mess-free formulas.
- Offering extended product stability, maintaining effectiveness over time.
Custom Formulations & Private Label Manufacturing
We offer tailored bespoke formulations to meet brand-specific requirements, including organic, alcohol-free, dermatologically tested, and cruelty-free options.
Advanced Manufacturing Capabilities
Our state-of-the-art facilities ensure high-quality production, safety, and consistency in every batch. Hydrokem offers:
- Custom Formulation Development – Our expert chemists and R&D team work closely with brands to develop unique, high-performance products.
- Flexible Packaging Solutions – We provide a variety of aerosol packaging options, including custom-designed cans, valves, and dispensing mechanisms to enhance brand identity.
- Regulatory Compliance – All our products meet stringent UK, EU, and FDA cosmetic safety regulations, ensuring your products are compliant and safe for consumers.
- Scalability & Production Efficiency – We accommodate both small-batch manufacturing for niche brands and large-scale production for global retailers.
Sustainable & Innovative Solutions
We are committed to eco-friendly aerosol manufacturing, offering:
- Sustainable propellants that minimise environmental impact.
- Recyclable and biodegradable packaging options to reduce waste.
- Green formulations free from parabens, sulphates, and unnecessary additives.
- Water-based and alcohol-free alternatives for skin-sensitive and organic brands.
Industry Overview and Market Trends
The UK's beauty and personal care industry has demonstrated remarkable resilience and growth in recent years, positioning itself as a significant contributor to the national economy. In 2024, consumer spending in this sector increased by 7.3% year-on-year, reflecting a robust demand for beauty products. Barclays
Market Size and Growth
The beauty and personal care market in the United Kingdom is projected to reach approximately £13.9 billion (US$17.52 billion) in 2025, with an expected annual growth rate of 2.07% from 2025 to 2029. This steady growth underscores the sector's resilience and adaptability to changing consumer preferences and economic conditions. Statista
Aerosol Segment Performance
Aerosol products have become integral to the cosmetics industry, offering convenience and enhanced user experience. The global aerosol market is projected to grow from USD 98.64 billion in 2025 to USD 158.42 billion by 2033, at a CAGR of 6.1%. In Europe, the aerosol market was valued at USD 30.2 billion in 2023, with expectations to expand at a CAGR of 7.1% from 2024 to 2030, driven by the increasing demand for beauty and personal care items. Straits Research, Grand View Research
Emerging Trends
- Sustainable and Ethical Practices: Consumers are increasingly prioritising products that are eco-friendly and ethically produced. This shift is driving brands to adopt sustainable sourcing, recyclable packaging, and cruelty-free testing methods.
- Influence of Social Media: Platforms like TikTok and Instagram have become pivotal in shaping beauty trends and consumer behaviour. The rise of 'skinfluencers' and beauty tutorials has led to increased demand for products that achieve viral popularity.
- Premiumisation: Despite economic challenges, there is a growing consumer inclination towards premium beauty products, perceived as essential for personal wellbeing. This trend has led to significant investments in luxury beauty retail spaces across the UK. The Guardian
- K-Beauty Influence: The Korean beauty trend, emphasising flawless 'glass skin', has seen a surge in the UK market. Brands offering hydrating serums and lotions have experienced increased sales, reflecting consumers' desire for radiant complexions. The Guardian
Manufacturing Facilities and Capabilities
Hydrokem’s state-of-the-art manufacturing facilities are specialised in the production of aerosol and bag-on-valve products. With seven aerosol production lines, including two dedicated healthcare lines, Hydrokem produces a wide range of products. Our capabilities include product development, blending concentrates, filling services, and secondary packaging, ensuring a full turnkey service from concept to delivery.
Aerosol Cans - Product Parameters and Specification
Hydrokem manufactures aerosol products in aluminium and tinplate containers, offering can diameters from 35mm to 66mm and fill sizes ranging from 25ml to 600ml. We work with various propellants, such as butane, DME, nitrogen, and compressed air. Our expertise also includes filling liquids of different viscosities and powder suspensions, with precise recirculation technology.
Meeting UK and Global Standards
Hydrokem ensures all products meet both UK and global regulatory standards. With dedicated lines for healthcare and medical devices, we prioritise strict compliance in every process. We maintain our understanding of international standards, allowing us to serve markets with specific requirements, such as low-VOC products for the U.S.
Flexibility and Scalability
Hydrokem’s manufacturing capabilities offer unparalleled flexibility and scalability. Our production lines can handle varying product types, from household and personal care items to specialist medical devices. With interchangeable lines for bag-on-valve and aerosol products, we can accommodate small and large production runs, while adapting to your specific product needs. This ensures efficient scaling, as required.
Frequently Asked Questions About Aerosols in Cosmetics Sector
What types of cosmetic aerosols can Hydrokem manufacture?
Hydrokem specialises in the production of various cosmetic aerosol products, including hairsprays, dry shampoos, deodorants, self-tanning sprays, shaving foams, body mists, and sun protection sprays. We also offer custom formulations to meet specific brand requirements.
Does Hydrokem offer private-label aerosol manufacturing?
Yes! We provide private-label and contract manufacturing services, allowing brands to create their own unique aerosol products under their branding. We can assist with formulation, packaging, and regulatory compliance.
Are Hydrokem’s aerosol products compliant with UK and EU regulations?
Absolutely. All of our products are manufactured in compliance with UK, EU, and FDA regulations, ensuring they meet the highest safety and quality standards. We also adhere to Good Manufacturing Practice (GMP) for cosmetics.
Can Hydrokem create custom formulations for my brand?
Yes, we specialise in custom formulations, working closely with brands to develop unique products. Whether you need an alcohol-free deodorant, an organic self-tanning spray, or a dermatologically tested hair mist, our team can create tailored solutions.
What are Hydrokem’s sustainability initiatives in aerosol manufacturing?
Sustainability is a key focus at Hydrokem. We use eco-friendly propellants, recyclable packaging, and biodegradable materials wherever possible. Additionally, we offer water-based formulations and alternative dispensing systems to reduce environmental impact.
How can I start working with Hydrokem for my cosmetic aerosol products?
Getting started is simple! Contact us today to discuss your project, request samples, or learn more about our custom aerosol manufacturing services. Our team will guide you through the entire process, from formulation to production and packaging.
