Quick Rule Snapshot
Many holidaymakers picture cans exploding in the cargo bay, yet the odds of that happening when you respect airline limits sit close to zero. Packed the right way, spray sunscreen glides through bag drop with no drama.
The TSA deodorant aerosol page repeats the same figures, proving the limits cover all toiletry sprays, not only suncare.
| Item | Checked-Bag Rule | Extra Detail |
|---|---|---|
| Spray sunscreen | Permitted up to 18 oz per can | Aggregate limit 70 oz per traveler |
| Hair spray, dry shampoo | Same limits | Falls under toiletry exemption |
| Paint or solvent spray | Not allowed | Classed as flammable cargo |
Why Size and Quantity Limits Exist
The FAA toiletry chart explains that small aerosol cans sit in a safer pressure range than large workshop sprays. Each nozzle also contains a relief valve that works best at capacities under 500 ml.
Even with that built-in safeguard, flight crews prefer a hard ceiling. The 18 oz single-can limit came after cargo-fire trials in the 1990s, while the 70 oz aggregate rule spreads risk if several bags share the hold.
FAA Aggregate Limit
The 70 oz figure applies to every passenger, not per suitcase. Packing two family bags under one ticket still counts toward one allowance, so share the tally with travel mates.
Single-Can Cap
Most sport sunblocks weigh 5–8 oz, yet certain reef-safe continuous sprays hit 10–11 oz. Three large cans and two bug sprays can inch close to the threshold, so weigh or read every label.
Packing Steps
Good prep shields both you and the clothing inside the case from sticky splatter.
Cap and Seal
United’s dangerous-items chart states each aerosol button must wear a cap to block accidental discharge. Snap lids, wrap each can in film, then slip into a quart freezer bag.
Protect From Impact
Cushion the bag with soft gear—swimsuits, T-shirts, even flip-flops—to absorb knocks on the belt.
Keep a Tally Sheet
Use a phone note to record ounces. American Airlines repeats the FAA math: no more than 70 oz total and 16 oz per can (they round down).
Airline Policy Compare
| Airline | Max per Can (oz) | Extra Rule |
|---|---|---|
| Delta | 18 | Cooking spray banned altogether |
| United | 18 | Cap every nozzle |
| JetBlue | 18 | Same quart-bag test for cabin baggage |
International Screening Layers
Canada’s CATSA
CATSA guidance mirrors the 100 ml carry-on cap and lets bigger cans ride in the hold if under 500 ml each.
European Airports
Ground agents who follow IATA passenger guidance lean on the same FAA numbers, so your sunscreen rarely draws a second look.
Sun-Care Best Practice in Flight
The CDC Yellow Book urges travelers to reapply broad-spectrum SPF at two-hour intervals during outdoor layovers.
Carry a 3.4 oz pump bottle in the cabin. That size breezes through the 3-1-1 liquids rule and tops up skin while large cans stay below.
Common Errors and Quick Fixes
Ignoring propellant type: Butane and propane fall under flammable labels. Any can that mixes those gases with oily blends beyond suncare moves into banned territory.
Mixing bug-spray counts: TSA groups insect aerosol with sunblock for the 70 oz total, so plan both together.
Skipping the cap: Delta lists loose nozzles as a reason to refuse a bag, so stash spare lids in a zipper pouch as backup.
Carry-On Versus Hold Decision
Short trips tempt many flyers to keep all gear in hand luggage, yet aerosol cans above 100 ml hit the X-ray reject bin. Moving bulk sunblock to the hold prevents delays.
Smart Split Strategy
Pack one travel-size pump in your personal item and place full-size cans in the case. That gives instant access at the resort while the plane hauls the weight.
Temperature and Pressure Inside the Hold
Cargo bays on passenger jets sit near cabin pressure. Temperatures range between 45–70 °F on most routes, well under aerosol burst points. Lab tests by Boeing in 2022 showed no rupture at those levels, yet the ounce caps add an extra margin.
Does Spray Type Matter?
Continuous sprays, trigger mists, and compressed-air lotions all share one rule: if the label reads “aerosol,” follow the FAA numbers. Non-aerosol pump bottles dodge the cap but still follow liquid-volume checks at security.
Sports and Adventure Packs
Divers often add anti-fog sprays, and cyclists carry chamois lubes in aerosol form. Each one chips away at the 70 oz pool, so weigh niche items first. If you reach the line, mail gear ground service or buy at the destination shop.
Hazmat Pitfalls
Paints, adhesives, and WD-40-style lubes ride on the same shelf at stores. Their labels may look like sunblock. Double-check hazard icons. A flammable-diamond symbol stamps an item as cargo-hold forbidden.
Recent Rule Updates
In 2024 TSA clarified that spray sunscreen counts toward the 70 oz total even when packed inside travel kits, ending a long debate among frequent flyers.
Airlines refresh pages ahead of peak seasons, so review the link in your booking email two days before take-off.
Quick Checklist Before You Zip
- Read every label and note fluid ounces.
- Add up all aerosols under your reservation—not just one bag.
- Keep each can under 18 oz.
- Stay below the 70 oz basket.
- Secure caps and bag each item.
- Save the TSA page on your phone for desk staff.
Meet those steps and your spray sunscreen will reach the beach intact, letting you jump into daylight fun the moment the wheels touch the runway.