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Oct 2023

The Science Behind Perfecting Flexible Package Seal Integrity

The Science Behind Perfecting Flexible Package Seal Integrity

Flexible packaging has become increasingly popular in various industries due to its versatility and cost-effectiveness. It is used for packaging a wide range of products, including food, pharmaceuticals, electronics, and more. It includes materials like pouches, bags, sachets, and wraps made from materials such as plastic, foil, paper, and laminates. Flexible packaging offers several advantages, such as being lightweight, space-efficient, and customizable in terms of design.

Flexible package seal integrity testing is of paramount importance due to its direct impact on product quality, safety, and consumer satisfaction. A secure and intact seal serves as the primary defense against external factors that could compromise the contents of the packaging. This includes preventing the ingress of moisture, oxygen, and other contaminants, all of which can adversely affect the product's shelf life, flavor, texture, and overall quality. A compromised seal not only risks the product's integrity but also raises concerns related to food safety and hygiene. In industries such as food and pharmaceuticals, maintaining seal integrity is vital to prevent potential health hazards and economic losses.

Furthermore, a strong focus on flexible package seal integrity testing is crucial for businesses aiming to uphold their brand reputation and avoid costly recalls. Products with compromised seals could lead to customer dissatisfaction. By implementing rigorous seal integrity testing protocols, manufacturers can ensure that their products remain fresh, safe, and free from contaminants, thereby safeguarding their brand's image and preserving customer loyalty.

Package seal quality inspection using Airborne Ultrasound Technology

PTI's Airborne ultrasound technology is a non-destructive, non-invasive method for seal integrity testing of flexible packages. It is a deterministic, quantitative test method and also an ASTM Test Method F3004-13. It is based on the principle that ultrasound waves are reflected at different rates depending on the density of the material they are traveling through. When ultrasound waves are transmitted through a package seal, any defects in the seal will cause the signal waves to be reflected differently, resulting in a change in the signal strength.

Airborne ultrasound technology is a versatile and reliable method for testing seals on a wide variety of flexible packaging materials, including films, foils, laminates, and pouches. It is also capable of testing seals on a variety of product types, including food and beverage products, pharmaceutical products, and medical device products.

PTI offers two configurations of Airborne ultrasound testing technology: Seal-Scan and Seal-Sensor. Seal-Scan is a high-resolution method that inspects and analyzes pouch seals non-destructively offline. Seal-Sensor is designed for 100% online pouch seal inspection.

Benefits of Airborne Ultrasound Technology

  • Non-destructive and non-invasive
  • Deterministic, quantitative test results
  • ASTM Test Method F3004-13 compliant
  • Capable of testing a wide range of flexible packaging materials
  • Detects a variety of seal defects, including leaks, misaligned seals, incomplete seals, missing seals, channel defects, pin holes, and porosity
  • High-speed inspection capabilities
  • Easy to integrate into production lines

The science behind perfecting flexible package seal integrity is a multidimensional approach that combines technological advancements with a commitment to product quality, safety, and brand reputation. Airborne ultrasound technology is just one example of how innovative methods are used to ensure that the seals on flexible packages remain strong, secure, and reliable.

seal integrity testing, flexible packaging, seal quality inspection, airborne ultrasound technology

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