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Seal quality has a direct influence on product stability, cleanliness, and shelf life. For industries such as pharmaceuticals, medical devices, and food & nutrition packaging, being able to inspect seals without damaging the product or packaging offers clear advantages. Airborne ultrasound is a non-invasive method that evaluates seal quality through sound wave analysis. It allows manufacturers to identify issues like pouch seal voids, misalignment, and channel leaks—without the need to cut open or alter the package. This method supports consistent inspection practices while helping maintain production efficiency.

A Leap from Traditional Methods

Conventional seal quality testing methods such as dye penetration, burst testing, and peel strength measurement are well-established but often destructive. These approaches require opening or damaging the package, leading to sample waste and additional handling. They also tend to focus on random sampling, which means some defects may go undetected.

Airborne ultrasound offers a different approach. By transmitting high-frequency sound waves across the seal area, this method collects feedback on seal uniformity and strength. Variations in the signal reveal defects that may not be visible or detectable by other non-destructive means. The process is fast, repeatable, and does not rely on visual cues—making it suitable for both offline batch testing and inline inspection during production.

Use Cases Across Industries

Pharmaceutical Packaging

Sterile barrier pouches are widely used in the pharmaceutical industry to protect drug products and maintain stability throughout their shelf life. These packages must stay sealed through manufacturing, transport, and storage to prevent exposure to moisture, oxygen, or other contaminants. Small defects like microchannels or incomplete seals can compromise product integrity without visible signs. Airborne ultrasound offers a non-destructive method to evaluate seal quality by using high-frequency sound waves to detect hidden flaws. It allows manufacturers to inspect packages without breaking sterility, making it suitable for development, routine quality checks, and process control. This approach supports higher inspection rates, reduces product loss, and aligns with pharmaceutical packaging standards by enabling thorough, repeatable testing in regulated environments.

Medical Devices

Medical devices, including surgical kits, diagnostic equipment, and sterile disposables, rely on flexible barrier packaging that must remain sealed until use. Seals that appear intact may still contain inconsistencies that could affect sterility. Airborne ultrasound allows manufacturers to evaluate these seals without opening the packaging, reducing the need for destructive checks. By scanning the seal area, the system can highlight voids, seal folds, or misalignment that may not affect appearance but can impact barrier performance. The technology is adaptable to various packaging formats and helps manufacturers monitor production quality without slowing down operations. It supports more consistent inspection routines and helps reduce sample waste.

Food and Nutrition Products

Food and nutrition products often use vacuum-sealed or flexible pouches that must resist external contaminants and preserve freshness. Packaging failure can lead to spoilage, consumer dissatisfaction, and product recalls. Airborne ultrasound enables non-contact inspection of heat seals on production lines or in the lab. It helps detect issues like uneven pressure, foreign material in the seal, or channel leaks that may lead to gradual air or moisture ingress. This technology supports high-throughput environments by delivering fast, automated inspection, which helps manufacturers keep up with production demands while maintaining seal consistency. It also minimizes rework by identifying seal variations before distribution, supporting product shelf life and packaging performance.

Airborne ultrasound presents a practical way to inspect packaging seals without destroying the sample or slowing down production. Its application across multiple industries shows its versatility in addressing modern packaging needs. Whether used for pharmaceuticals, medical devices, or food products, this technology supports manufacturers in maintaining consistent sealing practices. By detecting small defects that could impact performance, it offers an added layer of quality assurance with minimal disruption.