Household aerosols are self-contained handheld devices for spraying products such as air fresheners, hairspray, surface cleaners, polishes, and deodorants. Industrial aerosols are similar devices for spraying: cleaners, lubricants, paints, and adhesives. They also have hospital and specific medical uses for spraying coagulants and disinfectants. Worldwide around 20 billion devices are manufactured annually and the UK has a major share of this market, manufacturing 5 billion units, second only to the USA. Led by the Californian Air Resources Board (CARB) in 2001, there is mounting pressure for the use of liquefied gas propellants (volatile organic compounds) in aerosol cans to be banned. This paper addresses the challenges of creating a fine spray using a pressurized inert gas (non-VOC) as the propellant for household aerosols. The spray produced has to achieve a relative performance to that of a traditional fine spray VOC propellant aerosol with regard to droplet size, reach, cone angle, and flow rate. The findings of this work have demonstrated that to achieve a sub-50-mu m (D-v,D-50) spray is extremely challenging when using compressed inert gas and single fluid alone. However, by bleeding air into the insert arrangement, a spray of 24 mu m (D-v,D-50) can be obtained and this is comparable in droplet size to that produced by a traditional fine spray VOC aerosol.