Application
Aluminium Slugs for Aerosol Cans
From perfumes and deodorants to pharmaceutical inhalers and household sprays — every monobloc aluminium aerosol can begins as a precision-engineered slug. We've supplied this industry for three decades.
The monobloc aluminium aerosol can — and the slug behind it
A modern aluminium aerosol can is a remarkable piece of engineering: a seamless, single-piece pressure vessel manufactured in seconds from a single slug of aluminium. The entire body, dome and base of the can are formed in one impact-extrusion stroke — no welds, no seams, no liner required for most contents.
That manufacturing process places very specific demands on the starting slug. The aluminium must flow plastically and uniformly during extrusion, the dome must form without thinning, and the walls must be consistent enough to pass burst-pressure testing at 1.5× rated working pressure. A defect in the slug — an inclusion, an inconsistent grain, an out-of-spec dimension — becomes a defect in every can extruded from it.
Aerosol product categories we serve
Western Metal Industries supplies aluminium slugs to can manufacturers serving every major aerosol category:
- Personal care — body sprays, perfumes, deodorants, antiperspirants, hair sprays, hair mousses, shaving foams
- Pharmaceutical — metered-dose inhalers (MDIs) for respiratory medicines, topical anaesthetic sprays, antiseptic sprays
- Hygiene and sanitizers — alcohol-based hand sanitizers, surface disinfectants, fabric refreshers
- Household — air fresheners, insecticides, oven cleaners, furniture polish
- Food — whipped cream chargers, cooking sprays (in regions where aluminium is approved for food contact)
- Industrial and automotive — lubricant sprays, degreasers, paint sprays, contact cleaners
What aerosol can manufacturers ask of us
Aerosol can manufacturing is a high-volume, high-tolerance business. A modern impact extrusion press produces 150–250 cans per minute, running 24/7. Even a 0.5% defect rate becomes thousands of rejected cans per shift. That's why the slug specification is so unforgiving:
- Diameter tolerance within ±0.1 mm — to fit the extrusion die without play or jamming
- Thickness tolerance within ±0.05 mm — to produce consistent can wall thickness
- Uniform Brinell hardness across the slug — to extrude evenly
- Surface finish free of pits and rolling marks — to take downstream lacquering and printing
- Lot traceability — for regulatory compliance in pharma and export markets
Our integrated manufacturing process — melting, casting, rolling, punching, annealing and finishing all under one roof at our Hadapsar and Bhandgaon plants — gives us the consistency our aerosol can customers depend on for uninterrupted production.
What we deliver to aerosol can manufacturers
A short list, but every item matters in high-speed extrusion.
Custom dome profiles
Flat, conical, spherical and bespoke taper profiles produced from your can drawings.
99.7% pure aluminium
EN AW-1050A primary aluminium — never secondary stock. Full chemical certificates per batch.
Tight dimensional tolerance
Diameter ±0.1 mm, thickness ±0.05 mm. Engineered for high-speed extrusion lines.
Decoration-ready surface
Vibrated and tumbled finishes prepared for downstream lacquering, printing and anodising.
Export-ready packaging
VCI-lined cartons, fumigated pallets — surface protected through sea-freight transit.
Pharma-grade documentation
Full lot traceability and chemical certificates required for pharmaceutical aerosol applications.
Recommended product
For aerosol can manufacture, specify our Domed & Taper slugs.
Domed & Taper Slugs →
Pre-shaped aluminium slugs engineered for monobloc aerosol can production. 9.8 – 135.8 mm diameter, custom dome profiles available. EN AW-1050A grade, 99.7% pure.
View product specifications →Frequently asked questions
Which aluminium grade is best for aerosol can manufacturing?
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EN AW-1050A is the global standard for aerosol cans, offering the right balance of ductility (for impact extrusion) and strength (for pressure containment). EN AW-1070A may be used for higher-purity applications such as pharmaceutical metered-dose inhalers. Both grades are produced by Western Metal Industries at 99.7% purity.
What pressure ratings can aluminium aerosol cans achieve?
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Standard monobloc aluminium aerosol cans are rated for 6–15 bar working pressure with burst-pressure testing required at 1.5× rated pressure. The slug profile (domed or tapered), wall thickness and alloy choice together determine the achievable pressure rating.
Can aluminium aerosol cans be recycled?
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Yes. Aluminium aerosol cans are infinitely recyclable and one of the most sustainable packaging formats available. The monobloc construction (single material, no liners required for most contents) makes them easier to recycle than steel cans or laminated tubes.
What is the difference between a monobloc and a three-piece aerosol can?
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A monobloc aluminium aerosol can is produced from a single slug in one impact-extrusion stroke — there are no side seams or base seams. A three-piece (typically steel) can has a body, a base and a top welded together. Monobloc cans are lighter, leak-resistant, and preferred for premium personal-care and pharma applications.
Do you supply slugs for export-grade aerosol cans?
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Yes. We supply Indian and overseas can manufacturers whose cans are exported globally, including to markets with stringent compliance requirements (US DOT, EU TPED, UN dangerous-goods packaging). Our slugs are produced to dimensional and metallurgical specifications that enable our customers to meet these compliance regimes downstream.
Discuss your specifications with our team
India's largest aluminium slug manufacturer. Serving 50+ countries since 1978.