Global Aviation Compliance

Engineering the Perfect Travel Container

From the physics of cabin pressure to the strict geometry of the “Quart Bag.” We manufacture 100ml (3.4oz) packaging solutions that guarantee a hassle-free security screening experience for travelers worldwide.

Decoding the Global “3-1-1” Standard

Since 2006, the Transportation Security Administration (TSA), alongside ICAO (International Civil Aviation Organization), has enforced strict limitations on Liquids, Aerosols, and Gels (LAGs) in carry-on luggage. For B2B packaging buyers, compliance is not just about size—it’s about usability and verification.

The “Volume Marking” Mandate

A common failure point in travel packaging is the lack of clear labeling. Airport security officers are trained to confiscate unmarked bottles, even if they appear small. Golden Soar’s solution: We incorporate permanent, in-mold embossing of the volume (e.g., “100ml / 3.4oz”) on the base or shoulder of every travel SKU. Unlike printed labels that can rub off, embossed markings ensure the bottle remains compliant for years of travel.

The “3-1-1” rule is the universal language of air travel:

3.4 Ounces (100ml): The absolute maximum capacity per individual container.
1 Quart Bag: All containers must fit inside a single, clear, resealable bag.
1 Bag Per Person: Efficiency is key; bulky packaging wastes precious allowance.

Flat Oval Bottles Optimized for Quart Bags

Figure 1: “Flat-Oval” profiles maximize volume density within the TSA bag.

The Physics of Leakage: Boyle’s Law

Why do shampoos explode in suitcases? The answer lies in atmospheric pressure differentials. At sea level, pressure is approx. 14.7 psi. At a cruising altitude of 30,000 feet, the cabin is pressurized to the equivalent of 8,000 feet (approx. 10.9 psi).

The Delta-P Problem

This creates a pressure differential (Delta-P) of roughly 4 psi. The air trapped inside a rigid bottle (like glass or hard PET) expands as the external pressure drops. Because the bottle walls cannot expand, the expanding air forces the liquid contents out through the path of least resistance—usually the thread of the cap.

Our Engineering Solution

We approach this physics problem with two distinct technologies:

Elastic Expansion (Silicone/Soft PE): By using flexible materials, the bottle body is allowed to expand slightly under pressure (like a balloon). This volume increase accommodates the expanding air, neutralizing the internal pressure spike and preventing leakage.
Cross-Slit Valve Technology: For our premium travel series, we install a silicone check-valve in the cap. This valve remains mechanically sealed against the 4 psi internal pressure. It only opens when the user applies specific manual squeeze force (typically >10 psi), guaranteeing zero passive leakage.

Silicone Travel Bottles Expansion Diagram

Figure 2: Flexible silicone walls absorb pressure changes.

Material Science: Selecting the Right Substrate

Not all materials are suitable for all toiletries. Chemical compatibility is critical for travel kits that may hold anything from sunscreen to mouthwash.

재료	Travel Pros	Travel Cons	최상의 대상
LSR Silicone (Liquid Silicone Rubber)	Flexible: Adapts to pressure changes. Soft Touch: Premium feel. Squeezable: 100% evacuation.	Permeability: Not compatible with silicone-based serums or high-alcohol fluids (may sweat).	Shampoo, Conditioner, Lotion, Sunscreen (Cream).
PE(폴리에틸렌) (HDPE / LDPE)	Chemical Resistance: Excellent for almost all formulas. Durability: Impact resistant (won’t crack if dropped).	Aesthetics: Usually opaque or semi-transparent (harder to see level).	Body Wash, Face Cleanser, Contact Lens Solution.
PET (Polyester) (Virgin / PCR)	Clarity: Glass-like transparency helps security screening. Barrier: Good for alcohol and oils.	Rigid: Does not expand; requires valve cap for flight safety.	Mouthwash, Toner, Hair Oil, Makeup Remover.
알루미늄 (Epoxy Lined)	Protection: Blocks UV light completely. Temperature: Stays cool.	Dent Prone: Can dent in luggage. Rigid: Needs locking pump.	Hair Spray (Aerosol), Solid Tablets, Creams.

The “Quart Bag” Ecosystem

A travel kit is not complete without the outer bag. TSA regulations require a “clear, quart-sized, resealable bag.” We offer customizable outer packaging that meets these specs while elevating your brand.

EVA vs. PVC: The Sustainability Shift

Traditionally, clear bags were made of PVC (Polyvinyl Chloride). However, PVC can become brittle in the cold cargo hold of a plane and is less eco-friendly. Golden Soar recommends EVA (Ethylene Vinyl Acetate) 또는 TPU (Thermoplastic Polyurethane).

Softness: EVA/TPU remains soft and flexible even at freezing temperatures.
Clarity: TPU offers superior optical clarity for security scanning.
Eco-Friendly: Non-toxic, chlorine-free, and recyclable.

We also reinforce the zipper mechanisms to withstand the “over-stuffing” typical of travelers.

High Quality EVA Travel Bag Zipper Detail

Figure 3: Reinforced TPU/EVA bags pass the “Burst Strength” test.

Aviation Compliance FAQ

Does “100ml” include the bottle weight or just the liquid? +

The rule applies to the capacity of the container, not the amount of liquid inside. A 200ml bottle that is half-full (containing 100ml) is NOT allowed. The bottle itself must have a maximum capacity of 100ml. This is why our 100ml bottles are strictly dimensioned to not look “oversized.”

Are “Airless Bottles” allowed on planes? +

Yes, and they are highly recommended. Airless bottles have no dip tube and contain no air pocket. Since there is no air to expand, they are virtually immune to cabin pressure leakage, making them the safest choice for expensive serums.

Can I bring Aluminum Aerosols (like shaving foam)? +

Yes, provided the container is 100ml or less. Our Mini Aluminum Aerosols are specifically designed for this. They feature a locking actuator cap to prevent accidental discharge inside the bag due to luggage compression.

What is the advantage of “Flat” bottles over round ones? +

It’s about volume density. A standard quart bag is 2D until filled. Round bottles create triangular gaps of wasted space between them. Flat or square bottles pack flush against each other, allowing a user to fit 5-6 bottles in a bag where only 4 round ones would fit.

Launch Your Global Travel Kit

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