When we dream of a non-destructive testing method, it's not just the packaging that's affected. This innovation, which more closely reflects the realities of product movement within the supply chain (such as the pressure exerted by outer packaging, grouping, or transit), ensures that the packaging remains intact because the pressure applied is adjustable, and the product retains its appearance—something not guaranteed by previous techniques. This is particularly true when flexible packaging incorporates a paper layer, which can be weakened by the vacuum process, for example.
The emergence of in-line non-destructive testing
The innovation lies in a device that checks the airtightness of packaging without damaging it. The system uses a probe with a flexible membrane that adheres to the packaging. A slight pressure regulation is applied within the chamber, and the airflow required to maintain this stable pressure is measured. The integration of the airflow needed to compensate for the loss provides an objective and quantifiable indicator of leakage, directly correlated to the size of the defect. This method is simple, robust (relatively insensitive to external variations), and requires neither perforation nor the use of tracer gas.
The most immediate impact is to free manufacturers from the compromises between precision, cost and production rate.
Safety, Speed and Cost Efficiency: a threefold strategic benefit!
The integration of this non-destructive testing brings major advantages to each stage of the value chain.
100% control and cost optimization
Unlike spot sampling, this technology is sufficiently fast
The economic benefit is twofold:
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- Zero sample loss: The tested packaging and the product remain intact and marketable, immediately reducing product and packaging losses and costs.
- Early detection of deviations: Immediate detection of a defect (such as incorrect sealing settings or a film change) prevents the production of large quantities of non-conforming products.
Quality management tool and enhanced traceability
This innovation transforms passive quality control into an active management tool. The measurement is objective and quantitative, capable of detecting micro-leaks invisible to the naked eye, with a detection threshold that can go down to approximately 5µm in diameter depending on the probe's holding time.
Each test generates precise data (pressure, flow rate, etc.) that can be archived for auditing, statistical process control (SPC), and continuous improvement. This not only demonstrates compliance with standards requirements (ASTM, DIN) and customer agreements, but also allows for the control of crucial engineering parameters such as the ideal air/gas volume (air-fill) in the packaging.
CSR compliance and the future of flexible packaging
The adoption of lightweight, bio-based, or cellulose-based packaging films is accelerating to meet the demands of Corporate Social Responsibility (CSR). These new materials are often more fragile. The palpation approach, avoiding the excessive stress of aggressive vacuum or puncture testing, is perfectly suited to these films. It even makes it possible to overcome the difficulties associated with paper-structured or Tyvek packaging by focusing solely on detecting weld defects.
By reducing waste, limiting scrap and facilitating the adoption of more sustainable materials, this technology aligns health safety, industrial performance and the environmental objectives of manufacturers.
Conclusion
Non-destructive leak testing using flow measurement is no longer simply an alternative to destructive methods. It has become an essential strategic tool for quality, food safety, and industrial performance. By combining reliability, speed, simplicity, and environmental responsibility, it guarantees product integrity (fresh, processed, preservative-free), extends shelf life, and strengthens consumer confidence, thus securing the entire value chain. Manufacturers who adopt this approach will not only be able to reduce their operating and quality costs, but above all, gain a decisive advantage in controlling their packaging processes.
