Burst Testing Seal Integrity
What Is the Burst Testing Seal Integrity Method?
Burst testing detects leaks and assesses the integrity of seals in packaging by inserting a needle probe through a self-sealed, adhesive-backed septum and filling it with gas until it ruptures. The highest measurement taken before the package bursts is recorded as the maximum pressure it can withstand, which operators can use to determine if a package will perform under various conditions and real-world scenarios.
Burst Testing ASTM Standards and Packaging Suitability
- Standard Test Methods for Internal Pressurization Failure Resistance of Unrestrained Packages — ASTM F1140/F1140M-13(2020)e1
- Standard Test Method for Burst Testing of Flexible Package Seals Using Internal Air Pressurization Within Restraining Plates — ASTM F2054/F2054M-13(2020)
- Nonporous sealed flexible packaging from a vacuum state to ample levels of headspace
- Rigid containers with flexible and non-flexible lid seals with medium to ample headspace — PET bottles and cans
- Air pillow packaging
- Filled and sealed pouches, cups and trays
- Sealed empty trays
- Tyvek® lidded blisters (Tyvek® will need to be covered with tape or adhesive)
- Medical device pouches
- Medical device trays
- Blood bags
- Cosmetic packaging
- Foil pouches
Advantages of Burst Testing
Burst testing determines the operating limits of packaging to ensure it meets safety standards in regulated industries. For example, compliance is critical when selling sterile packaging environments or products containing fluids or gases.
It’s also vital for quality control, allowing manufacturers to identify weaknesses or design flaws that could cause the packaging to fail. Manufacturers can then adjust the design, select better materials or adjust processes to enhance reliability before the product goes to market.
This seal integrity method also mitigates risk. By identifying points of failure before a product reaches consumers, brands can avoid costly recalls, warranty claims and potential legal action.
Disadvantages of Burst Testing
Burst testing is a destructive test method, as it involves inserting a needle probe and subjecting the packaging to increased pressure until it ruptures. This process typically renders the samples unusable and can introduce additional costs when further testing or analysis is required.
Burst testing is also heavily user-dependent, introducing the operator as a potential source of error. Sample preparation often requires manual handling and manipulation, potentially resulting in improper alignment, uneven stress distribution and variations in sample dimensions. These factors can impact test results and lead to inconsistencies in data.
Bubble Emission Package Leak Detection
What Is the Bubble Emission Package Leak Detection Method?
Bubble emission package testing works on the pressure differential principle and is an effective method for assessing the pressure resistance of seals in flexible packaging. It is widely used in Modified Atmosphere Packaging (MAP) environments.
During the test, the packaging is positioned in a transparent acrylic test chamber filled with water. Subjecting the headspace to a predetermined level of vacuum creates a pressure differential, causing the packaging to expand.
A stream of bubbles emitting from the packaging indicates the presence of a leak and allows the operator to pinpoint its location.
Relevant Standards and Packaging Suitability
- Standard Test Method for Determination of Leaks in Flexible Packaging by Bubble Emission — ASTM D3078
- Nonporous sealed flexible food and pharmaceutical and medical device packaging with medium to ample headspace
- Rigid containers with flexible and non-flexible lid seals with medium to ample headspace — PET bottles and cans
- Air pillow packaging
- Standard Test Method for Leakage Testing of Empty Rigid Containers by Vacuum Method — ASTM D4991 – 07(2015)
- Rigid containers with flexible and non-flexible lid seals
- Standard Test Method for Detecting Gross Leaks in Packaging by Internal Pressurization (Bubble Test) — ASTM F2096 – 11
- Vacuum packaged food, pharmaceutical and medical device packaging
- Nonporous flexible food, pharmaceutical and medical device packaging with limited or ample headspace
- Rigid containers with flexible and non-flexible lid seals
- Tyvek® food, pharmaceutical and medical device packaging
Advantages of the Bubble Emission Leak Detection Method
Bubble emission testing allows for the rapid detection of leaks in packaging. The presence of bubbles (or lack thereof) also provides immediate visual confirmation of a leak’s location.
As it is non-destructive to nonporous materials, bubble emission testing can be done repeatedly without compromising the material’s integrity.
This method is also straightforward and requires minimal training.
Disadvantages of Bubble Emission Testing
Bubble emission testing is best suited to detecting large leaks — it will not identify holes smaller than 20 µm. As it is a predominantly visual test, it cannot offer precise quantitative measurements, making it challenging to determine the exact rate of leakage.
This package leak detection method is also restricted by the size of the test chamber. Operators may need to select an alternative to test larger products that are not easily submerged.
Altitude Simulation Package Seal Integrity
What Is the Altitude Simulation Package Seal Integrity Test?
Altitude simulation is a testing method used to determine the integrity of package seals for products that will be transported via air or ground freight through mountainous regions, where there are extreme pressure fluctuations due to altitude changes.
An altitude simulation test is similar in concept to a bubble emission test, allowing products like the Dynascan LeakVIEW to be used. However, unlike in a bubble emission test, the chamber does not need to be filled with water.
Altitude simulation package testing is conducted by placing a sealed package into a chamber that can emulate the conditions encountered during transportation by simulating ascent and descent rates. To determine if the product can withstand the cyclic pressure changes, manufacturers evaluate the seal over a duration similar to how long the item would be in transit. If the seal is inadequate, the altitude simulation test will result in a leak or seal failure.
Relevant Standards and Packaging Suitability
- Altitude Simulation — ASTM D6653
- Nonporous, flexible food and pharmaceutical packaging with ample headspace
- Rigid containers with flexible and non-flexible lid seals with ample headspace
- Sachets, pouches, bags and MAP (flexible, nonporous materials)
- Flexible, nonporous packages, including bags and pouches containing solids (powders and medical devices)
- Sealed cups or trays containing solids (tablets, capsules, powders or devices)
- Sealed empty cups or trays
Advantages of Altitude Simulation
Altitude simulation testing is highly versatile and can detect gross and micron-sized leaks. With equipment like the Dynascan LeakVIEW Auto, the vacuum level and test duration can be input at the touch of a button using a programmable touch screen, ensuring repeatable and reproducible results regardless of operator skill.
This package seal integrity method also enables both destructive and non-destructive testing. With non-destructive testing, operators can assess package integrity without compromising or damaging a package.
However, a destructive altitude simulation test may be preferable:
- When the non-destructive method proves insufficient or inconclusive.
- To examine the internal components of a package.
- To determine the cause of a leak.
- To bolster consumer trust by demonstrating seal performance.
- To provide conclusive evidence of seal integrity to comply with regulations.
The ability to select non-destructive and destructive testing provides manufacturers with greater flexibility.
Disadvantages of Altitude Simulation
While altitude simulation package leak testing equipment is easy to use and requires minimal training, operators must set the correct parameters to ensure accuracy and efficiency. Errors made during the programming process can waste considerable time — with tests taking hours or days depending on the packaging material measured, the altitude and intended duration of the flight simulation, and whether the test is destructive or non-destructive.
Like other package leak detection and seal integrity testing methods, altitude simulation can not detect leaks smaller than 20 µm.
Learn More about Leak Detection and Seal Integrity
Seal integrity testing is pivotal in protecting against leaks or defects and ensuring packaging is safe and effective across multiple use cases and industries. Learn more about leak detection methods and applications by using the links below:
- Learn more about leak detection and seal integrity testing and why it is important
- Learn more about the methods of leak detection and seal integrity testing available
- Learn more about force decay, seal strength and vacuum decay testing
- Learn more about dye penetration seal integrity testing
- Learn more about flow rate seal integrity testing
- Learn more about how to select the right leak detection and seal integrity method for your business
- Learn more about how frequently seal integrity testing should be carried out
- Learn more about how documents and records of seal integrity testing can be stored
Explore Our Range of Leak Detection and Seal Integrity Testing Equipment at LIMAB UK
Our team of product specialists at LIMAB UK get to know the unique needs of your business and provide one-to-one support to find the best package leak detection and seal integrity testing method for you. Request a consultation today by calling +44 (0)1823 668633, emailing hello@limab.co.uk or submitting a contact form.
