When we dream of a non-destructive tester, it is not just the packaging that is involved. In this innovation, which is even closer to the reality of product circulation in the supply chain (such as the pressures of outer packaging, grouping, or transit), the packaging is not weakened, as the pressure can be adjusted, and the product retains its appearance, which is not guaranteed by previous techniques. In particular, when flexible packaging incorporates a paper layer, this can be weakened by vacuuming, for example.

The emergence of online non-destructive testing

The innovation is based on a device that checks the tightness of packaging without damaging it. The system uses a sensor with a flexible membrane that is pressed against the packaging. A slight pressure adjustment is applied in the chamber, and the air flow required to maintain this stable pressure is measured. The integration of the air flow required to compensate for the loss is an objective and quantifiable indicator of leakage, directly correlated to the size of the defect. This method is simple, robust (not very sensitive to external variations), and requires no perforation or use of tracer gas.

The most immediate impact is to free manufacturers from compromises between accuracy, cost and speed.

Safety, Speed and Economy: the triple strategic benefit!

The integration of this non-destructive testing brings major advantages at every stage of the value chain:

100% inspection and cost optimisation

Unlike spot sampling, this technology is fast enough to envisage 100% continuous inspection at the end of the sealing process, even on high-speed lines, and at the very least, to significantly increase the sampling rate. This speed is made possible by pneumatic information transmission and the ability to integrate synchronised dynamic systems on the conveyor, or asynchronous systems using robotic arms.

The economic benefit is twofold:

• Zero sample loss: The tested packaging and 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 change in film) prevents the production of large quantities of non-compliant products.

Quality control tool with enhanced traceability

This innovation transforms passive quality control into an active control tool. Measurements are objective and quantitative, capable of detecting micro-leaks invisible to the naked eye, with a detection threshold that can be lowered to approximately 5µm in diameter depending on the probe dwell time.

Each test generates accurate data (pressure, flow rate, etc.) that can be archived for auditing, statistical process control (SPC) and continuous improvement. This not only proves compliance with standards (ASTM, DIN) and customer agreements, but also controls 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 lighter, bio-based or cellulose-based packaging films is accelerating in response to Corporate Social Responsibility (CSR) requirements. These new materials are often more fragile. The palpation approach, which avoids the excessive stress of aggressive vacuuming or puncturing, is perfectly suited to these films. It even solves the difficulties associated with paper or Tyvek packaging by focusing solely on detecting seal defects.

By reducing waste, limiting scrap and facilitating the adoption of more sustainable materials, this technology aligns health and safety, industrial performance and environmental objectives for 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, MAP, preservative-free), extends shelf life and boosts consumer confidence, thereby securing the entire value chain. Manufacturers who adopt this approach will not only be able to reduce their operating and non-quality costs, but above all gain a decisive advantage in controlling their packaging processes.