Developing an innovative aerosol or Bag-on-Valve (BoV) product requires deep expertise in formulation, sustainability, and regulatory compliance. Whether you're launching a new product, enhancing an existing formula, or transitioning to more sustainable solutions, our team at Hydrokem offers a comprehensive, end-to-end development service.
With years of hands-on experience in the automotive, healthcare, personal care, pet care, and household industries, we help product development managers transform ideas into market-ready solutions. Our state-of-the-art R&D capabilities, stringent quality control processes, and regulatory expertise ensure your product meets industry standards while staying ahead of consumer trends.
Explore our specialised services below to see how we can help bring your next aerosol or Bag-on-Valve product to life.
Product Formulation
Our Approach to Formulation
- Understanding Your Needs – We collaborate with your team to understand product goals, desired properties, and industry regulations.
- Ingredient Selection & Compatibility Testing – Using high-quality, sustainable ingredients, we ensure compatibility with propellants, solvents, and active ingredients.
- Prototype Development & Stability Testing – Our R&D team develops multiple prototypes, conducting rigorous stability and performance tests.
- Regulatory Compliance – We navigate complex UK and EU regulations, ensuring your product complies with REACH, CLP, and other relevant standards.
With our cutting-edge formulation expertise, you gain a product that is not only high-performing but also optimised for safety and longevity in the market.
Product Improvement
If you have an existing aerosol or Bag-on-Valve product that requires enhancement—whether it's better spray performance, improved shelf life, or a reformulation to meet new regulations—Hydrokem provides specialist product improvement solutions.
Our Enhancement Strategies
- Performance Optimisation – We refine spray patterns, product viscosity, and dispersion for better user experience.
- Stability & Shelf-Life Enhancement – Using advanced testing, we improve product longevity and resistance to environmental changes.
- Compliance & Safety Upgrades – Reformulating to meet evolving UK & EU safety standards.
- Cost Optimisation – Identifying cost-effective raw materials and production processes without compromising quality.
With our expertise, you can breathe new life into existing products, ensuring they remain competitive in a changing marketplace.
Making Your Product More Sustainable
Sustainability is a key priority for businesses today, with both consumers and regulatory bodies demanding eco-friendly product alternatives. Hydrokem offers sustainable product development services, helping companies reduce their environmental impact while maintaining top-tier product performance.
How We Make Your Aerosol or BoV Product More Sustainable
- Eco-Friendly Formulations – We replace harmful ingredients with biodegradable, non-toxic alternatives.
- Propellant Optimisation – Transition to low-GWP (Global Warming Potential) or propellant-free options.
- Sustainable Packaging Solutions – We offer recyclable and refillable BoV packaging to reduce waste.
- Regulatory & Market Compliance – We ensure alignment with UK & EU sustainability regulations, including Extended Producer Responsibility (EPR) schemes.
A shift to sustainability isn’t just about compliance—it’s about
future-proofing your products while appealing to eco-conscious consumers.
New Product Introduction: A Full Turnkey Service
Launching a new aerosol or Bag-on-Valve product can be complex. Hydrokem simplifies the process with a full turnkey development service, handling everything from concept to commercialisation.
Our Full-Service Solution Covers:
- Market & Competitor Analysis – Identifying trends, gaps, and opportunities.
- Formulation & Prototype Development – Creating a bespoke product that meets performance and safety standards.
- Regulatory Support – Ensuring compliance with UK/EU regulations.
- Manufacturing & Scale-Up – Partnering with trusted manufacturers for efficient, cost-effective production.
- Quality Assurance & Stability Testing – Conducting rigorous testing to ensure product consistency.
- Packaging & Labelling Compliance – Offering innovative packaging solutions that meet branding and sustainability goals.
From concept to shelf, our turnkey service ensures a smooth, efficient, and compliant product launch, allowing you to focus on market growth and customer engagement.
What is Bag-on-Valve (BoV) technology, and how does it differ from traditional aerosol systems?
Bag-on-Valve (BoV) technology is a modern aerosol dispensing system where the product is stored in a flexible bag inside the can. Unlike traditional aerosols where the product and propellant mix, BoV technology separates them. This separation prevents contamination, extends shelf life, and ensures nearly complete product usage, reducing waste.
BoV technology also offers 360-degree usability, meaning the product can be dispensed in any orientation without losing pressure. Additionally, BoV allows for the use of compressed air or nitrogen as a propellant, eliminating the need for volatile organic compounds (VOCs) commonly found in traditional aerosols. This makes it a more environmentally friendly choice.
Industries such as personal care, pharmaceuticals, food, and household products benefit greatly from BoV due to its precise and consistent spray performance, minimal waste, and compliance with stringent environmental regulations.
What are the environmental benefits of Bag-on-Valve technology?
BoV technology is considered one of the most sustainable aerosol solutions available today. By using compressed air or nitrogen instead of hydrocarbons, it significantly reduces the emission of VOCs, which contribute to air pollution and climate change. Additionally, BoV systems allow for nearly 99% product usage, minimising residual waste in packaging.
Another major advantage is that BoV cans are typically made from 100% recyclable materials, such as aluminium, contributing to circular economy principles. With growing regulatory pressure for brands to reduce their carbon footprint, transitioning to BoV technology can help businesses meet sustainability goals and comply with environmental standards such as the UK Plastic Packaging Tax and Extended Producer Responsibility (EPR) schemes.
How long does it take to develop and launch a new aerosol or BoV product?
The development timeline for an aerosol or BoV product can vary depending on factors such as formulation complexity, regulatory compliance, and production requirements. Typically, the process takes 6 to 12 months, including R&D, prototype development, stability testing, and regulatory approvals.
At Hydrokem, we streamline this process by providing a turnkey solution, which includes market analysis, product formulation, regulatory compliance, and manufacturing coordination. Our in-house expertise and partnerships with leading aerosol manufacturers allow us to accelerate the time-to-market while maintaining high-quality standards.
What industries benefit the most from Bag-on-Valve technology?
Bag-on-Valve (BoV) technology is highly versatile and is used across a wide range of industries that require precision dispensing, extended shelf life, and minimal product waste. Some of the key industries benefiting from BoV technology include:
Personal Care & Cosmetics – Used in sunscreens, deodorants, hair sprays, and skincare products due to its ability to dispense without propellants affecting the formulation.
Pharmaceuticals & Healthcare – Ideal for nasal sprays, wound care, and pain relief products that require sterile and precise application.
Food & Beverage – Frequently used in cooking sprays, whipped creams, and edible oils due to its contamination-free and waste-reducing properties.
Household & Industrial – Perfect for cleaning sprays, lubricants, and pest control solutions where efficient and controlled dispensing is essential.
Pet Care – Applied in medicated sprays, grooming products, and odour removers that require an even, targeted application.
BoV’s ability to reduce product waste, enhance safety, and eliminate harmful propellants makes it a preferred choice for brands looking to improve sustainability and consumer convenience.
What are the cost implications of switching from traditional aerosol systems to BoV technology?
The cost of transitioning from a traditional aerosol system to Bag-on-Valve (BoV) technology can depend on several factors, including formulation adjustments, packaging material costs, and filling process changes. While the initial setup cost may be higher, the long-term benefits often outweigh these expenses.
Key Cost Considerations:
Initial Investment in Packaging – BoV requires specialised packaging with an internal flexible bag and a separate propellant chamber.
Filling Process Adjustments – The manufacturing process differs from traditional aerosols, necessitating specific equipment and handling procedures.
Sustainability Savings – Since BoV systems use nearly 100% of the product, there is less product waste, reducing overall costs over time.
Regulatory Compliance – BoV helps companies avoid future regulatory expenses related to the restriction of volatile organic compounds (VOCs) and other environmental penalties.
Many companies find that despite the higher upfront costs, BoV technology leads to better product efficiency, reduced environmental impact, and improved consumer satisfaction, ultimately leading to higher profitability.
