twistMist: Engineering the future of aerosol delivery
Published Wednesday May 28, 2025Aerosol sprays have remained virtually unchanged for decades until now. Alternative Packaging Solutions (APS) disrupted the category with twistMist™, a twist-activated, propellant-free spray system that delivers consistent, even coverage without the need for pressurized cans or harmful chemicals.
To ensure twistMist was ready for commercial success, APS partnered with Kinetic Vision to provide advanced engineering support across product validation, performance testing, and consumer readiness. Our team used a combination of high-resolution scanning, simulation, and image-based spray analysis to optimize spray pattern density, prevent leakage, and improve real-world usability across personal, home, and specialty care applications.
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How we helped make twistMist flawless
Leak prevention and design optimization
- Conducted 4D CT scanning to analyze internal forces and mitigate leakage issues
- Identified out-of-tolerance components and collaborated with APS on design improvements
- Completed high-resolution nozzle scans to compare geometries and enhance performance
- Used simulation and sensory analysis to refine spray angle, droplet size, and wetness
- Improved spray consistency and coverage, achieving 2-4x better performance
Material and component evaluations
- Investigated how material variance impacted valve production quality
- Diagnosed seal defects in check valves using advanced scanning
- Optimized component and assembly stack-ups for better function and consistency
- Tested packaging-product interactions across various recyclable materials
Performance and compatibility testing
- Performed spray pattern benchmarking to ensure even, reliable application
- Conducted compatibility testing with multiple formulations pre-market
- Verified product performance across personal care, suncare, and home categories
- Validated visible dosing and refillable design for consumer confidence
The results? A mist so consistent it eliminates the need to rub in sunscreen, a refillable design that reduces waste, and a visible metered dose window, allowing consumers to apply the right amount of product every time. The technology has been recognized for its sustainability benefits, winning the 2023 U.S. Plastics Pact Sustainable Packaging Innovation Award in the Reuse/Refill category. It was also featured on the cover of World Aerosols for two years in a row.
As twistMist technology expands into categories like personal, home, and specialty care, APS has launched UV Defense™, a sun care brand built to showcase the system’s potential. Kinetic Vision is proud to have played a critical role in validating and accelerating this packaging innovation.
