Aerosol propellants are essential in delivering a wide range of products in spray form, from domestic items to industrial applications. These propellants are compounds that apply pressure to eject the product from its container, transforming liquid or solid formulations into a fine mist or foam upon release. Because of their durability and effectiveness, chlorofluorocarbons (CFCs) were once widely utilized as propellants. However, due to their negative impact on the ozone layer, they were phased out under the Montreal Protocol. As a result, businesses turned to hydrocarbons such as propane, butane, and isobutane, which, while effective, posed flammability issues. To address safety issues, the industry began to investigate alternate propellants such as compressed gases (such as nitrogen), dimethyl ether (DME), and carbon dioxide (CO2). Non-flammable compressed gases are available, assuring safety during usage and storage. DME, a liquefied gas, has good solvent qualities and can be used to replace traditional propellants in an environmentally acceptable manner. Carbon dioxide, which is abundant and non-toxic, has attracted attention for its environmental benefits. However, because larger operating pressures are necessary for effective propulsion, stronger containers are required. Nonetheless, advances in container technology and formulation modifications have made CO2 a feasible option for certain uses, particularly in the food industry. Furthermore, new technologies are being developed, such as hydrofluoroolefins (HFOs), which are regarded as next-generation propellants. HFOs are engineered to have a low global warming potential (GWP) and no ozone depletion potential (ODP), allowing them to comply with severe environmental standards. These compounds are promising replacements for conventional propellants, balancing performance and sustainability. The nature of the product, intended spray characteristics, environmental impact, and safety issues all influence propellant selection. These criteria must be considered by industries when selecting propellants that meet both regulatory standards and consumer needs for effective, safe, and ecologically conscientious goods. Continued research and innovation attempt to improve propellant technology, with the goal of improving performance, lowering environmental impact, and increasing safety across a wide range of applications. As regulatory criteria change and customer tastes shift toward sustainability, the aerosol industry remains committed to developing propellant solutions that meet these new needs.
