FEA 623: Mechanical Resistance of Filled Aerosol Packs

Standard Overview

FEA 623 is an industry standard issued by the European Aerosol Federation (FEA) that defines a simplified hydraulic test method to evaluate the mechanical resistance of filled aerosol packs fitted with a valve.

Unlike FEA 621, which evaluates empty containers, FEA 623 assesses the complete aerosol system:

Container (metal or plastic)
Valve and dip tube
Clinch or crimp interface

Key insight: FEA 623 evaluates the mechanical integrity of a sealed, functional aerosol pack.

Scope and Applicability

The method applies to:

Metal aerosol containers (tinplate or aluminium)
Plastic aerosol containers
Containers fitted with a valve by clinching or external crimping

The test is primarily intended for:

Product development
Design validation
Comparative system evaluation

Important: This is a development and assessment method, not a regulatory replacement for water bath testing.

Safety Warning

The test may result in:

Sudden bursting of the aerosol pack
Ejection of the valve assembly

Appropriate shielding and operator protection are mandatory.

Safety rule: Never perform FEA 623 testing without a protective screen.

Test Equipment

Schematic diagram of FEA 623 hydraulic pressure test showing filled aerosol container connected to a pump system with pressure gauge and bottom injection of water — Schematic representation of the FEA 623 test method showing hydraulic pressurisation of a filled aerosol pack via bottom connection and pressure measurement system

The test setup requires:

Hydraulic pump
Pressure gauge with maximum pointer
Minimum scale resolution of 1 bar

Test Preparation

The test sequence is as follows:

A pump connector is assembled to the bottom of the container
An aerosol valve with dip tube is clinched or crimped onto the container
The container is completely filled with water at 20 ± 5 °C
The container is connected to the hydraulic pump

All trapped air must be removed by applying a small pressure (approximately 1 bar) and actuating the valve with the container inverted.

Engineering insight: Residual air dramatically increases stored energy and invalidates results.

Pump Connector Configurations

Screw fitting components for aerosol container bottom connection including threaded connector, sealing gasket, and locking nut — Components of a screw fitting used to connect the hydraulic pump to the drilled container base, including connector, gasket, and locking nut

Assembled screw fitting mounted on aerosol container base showing internal and external views with sealing gasket compressed — Assembled bottom connection showing gasket compression and sealing interface on the aerosol container

Two pump connection methods are permitted:

Drilled bottom with tyre valve (internal components removed)
Drilled bottom with screw fitting and gasket

The hole diameter:

Must not exceed 9 mm in any case

Must not exceed 20% of the container diameter

Important limitation: The drilled hole weakens the container and must be kept as small as possible.

Test Procedure

After preparation:

Pressurisation continues until leakage or bursting occurs

The container is pressurised hydraulically

Pressure increase rate must not exceed 1 bar per second

Rule: Controlled pressurisation is essential for meaningful mechanical resistance comparison.

Observed Failure Modes

During testing, deformation or failure may occur at:

Valve cup or centre boss
Container shoulder or cone
Cylindrical body
Container bottom
Valve–container junction

Hydraulic pressure testing of filled aerosol container showing bottom pump connection and valve leakage during pressurisation — Hydraulic pressurisation of a filled aerosol container showing bottom pump connection (left) and leakage occurring at the valve under increasing internal pressure (right)

Comparison of aerosol container base before and after FEA 623 pressure test showing intact base with pump connector and ruptured base with radial crack and deformation — Comparison of container base before and after FEA 623 testing, showing intact bottom connection (left) and base rupture with radial crack under internal pressure (right)

Reporting Requirements

The test report must include:

Details of container, valve, and clinch/crimp method
Sample size
Pressure at which deformation occurs, by component
Leakage locations
Pressure at bursting or valve blow-off

Engineering Significance

FEA 623 provides a fast, comparative method to:

Evaluate container–valve system robustness
Compare alternative materials or designs
Identify weak points in assembled aerosol packs

It is especially valuable during:

New product development
Valve or container redesign
Supplier qualification

System insight: FEA 623 bridges the gap between empty-container testing (FEA 621) and filled-pack regulatory tests (FEA 606).

Relationship with Other Standards

FEA 621 – Pressure resistance of empty containers
FEA 606 – Water bath testing of filled aerosol packs
ADR / RID – Transport regulations

Download the Standard PDF

FEA 623 standard describing a simplified hydraulic test method used to evaluate the mechanical resistance of filled metal and plastic aerosol containers fitted with valves. It defines pressurization procedures to identify deformation, leakage, or bursting, helping assess container strength during product development and safety testing.

Download FEA 623 (PDF)

Browse Aerosol Packaging

FAQ – Engineering & Development

No. It is a development and assessment method, used to support design decisions rather than regulatory approval.

Water eliminates variability from formulation behaviour and significantly improves test safety.

No. FEA 623 complements but does not replace regulatory water bath tests.

It allows controlled hydraulic pressurisation, but must be minimised to avoid distorting results.

The drilled hole alters container strength, so absolute pressure values must be interpreted comparatively.

Pony Ma | CEO

With 25 years of experience in metal packaging and international business, we are dedicated to providing sustainable packaging solutions through innovative aluminum technologies. And I regularly share insights on material innovation and global sourcing strategies to help brands stay competitive.

Welcome to connect with me on LinkedIn to discuss the latest industry trends.