Navigating airline security with aerosol products can be confusing. As a leading aerosol can manufacturer with decades of experience, we clarify the latest regulations (2024-2025) based on direct testing and international safety standards. This guide will help you travel safely and avoid confiscations at security checks.

Current Airline Rules: What the TSA and IATA Say

Let’s cut through the noise. The rules for traveling with aerosol cans hinge on their classification and placement. The table below summarizes the key 2025 requirements for personal travel:

But here’s a critical update for brands: the IATA’s latest guidelines now allow higher pressure limits (up to 300 kPa) for cans using sustainable propellants like HFO-1234ze. This change reflects the industry's effort to balance safety with environmental progress.

Why Aerosol Cans Are Restricted—A Technical Perspective​​

As an engineer, I often explain that the risks boil down to ​​pressure and flammability​​. At 30,000 feet, cargo hold temperatures can swing from -40°C to 50°C. Standard cans with hydrocarbon propellants (e.g., butane) may rupture or leak under these conditions. In 2023, the FAA documented 58 incidents involving aerosol-related pressure incidents.

Packing Tips from a Pro: Avoid These Common Mistakes

The biggest error? Assuming "non-flammable" means "risk-free." Even water-based aerosols can explode if damaged. Always: ​​

1. Cap the nozzle​​ with a protective cover (we include them with every ​​AeroGuard can​​). ​​

2. Wrap cans in a zip-lock bag​​ to contain leaks. ​​

3. Declare contents​​ if shipping commercially—using UN1950 labels is mandatory.

Pro tip: Our clients who use ​​custom-printed cans​​ with clear hazard symbols report fewer delays at security checks.

Your Partner in Compliant Can Manufacturing​​

At ​​GUANGZHOU MIJIA, we may not fill the cans, but we build the foundation for your product's safety and compliance. Our expertise lies in producing reliable, ​​UN-certified empty aerosol cans​​ that meet the strict standards required for global air transport. We understand the regulations because our clients live by them. If you're looking for a trusted manufacturing partner to supply the core component for your travel-safe aerosol products, we invite you to learn more about our ​​quality control process​​ and ​​standard can specifications

Key Takeaways for Safe Air Travel with Aerosols​​

In summary, the answer is ​​yes, with important conditions​​. Check for flammability warnings first. Adhere to the strict 100ml limit for carry-ons. For checked bags, respect the total weight limit. As manufacturers, we are committed to producing cans that meet the highest safety standards, including those required for air transport. When in doubt, always consult the latest TSA or your airline's website before flying. For businesses looking to develop air-travel-friendly aerosol products, partnering with an experienced manufacturer who understands these complex regulations is the first step toward success.