Common Failures In Pouch Packaging
Pouches are a go-to for flexibility and convenience, but they can fail in critical ways—from poor seals to punctures and delamination—that hurt performance and brand reputation. Understanding these failure points helps packaging teams design for real-world reliability.
Seal Failures
- Improper Seal Parameters: Inadequate temperature, pressure, or dwell time can lead to seal weakness or gaps.
- Contamination in Seal Area: Oils, powders, or debris interrupt adhesive bonding.
- Technology-Specific Issues: For example, cold-seal adhesives may struggle with migration in warm environments.
Key Tests:
- Seal Strength – ASTM F88/F88M-23: Measures the force needed to peel a seal.
- Dye Penetration – ASTM F1929-23: Reveals micro-channel leaks with colored dye application.
Punctures & Tears
- Thin Films: Save on cost but vulnerable to rough handling.
- Product Content: Granular or sharp-edged items can degrade film integrity.
- Transit Damage: Handling, stacking, or abrasion increases vulnerability.
Tip: For rougher applications, consider reinforced films or nylon layers.
Delamination
- Poor Adhesion Between Layers: Causes separation and weakened barrier performance.
- Environmental Stress: High humidity or heat can undermine lamination.
- Material Mismatch: Some layers simply don’t bond well together.
Tip: Match adhesives to substrate properties and test under realistic conditions.
Barrier Degradation
- OTR and WVTR Drift: EVOH’s oxygen barrier weakens under humidity, while metallized films can develop pinholes over time.
- Inconsistent PCR Film Quality: While desirable for sustainability, PCR variants may introduce variability in barrier integrity.
Tip: Define target OTR and WVTR values and validate using ASTM F1249 (WVTR) and ASTM D3985 (OTR).
Why This Matters
- For food, compromised seals mean spoilage and recalls.
- In pharma, even small leaks can breach sterility and regulatory compliance.
- Pet products can lose freshness and consumer trust fast.
Preventing these failures starts with engineered material selection, precise sealing validation, and in-line quality testing—not guesswork.
References
- ASTM International. (2023). ASTM F88/F88M‑23: Standard Test Method for Seal Strength of Flexible Barrier Materials. https://www.astm.org/f0088_f0088m-23.html Keystone Compliance+11ASTM International | ASTM+11ASTM International | ASTM+11The ANSI Blog
- ASTM International. (2023). ASTM F1929‑23: Standard Test Method for Detecting Seal Leaks in Porous Medical Packaging by Dye Penetration. https://www.astm.org/f1929-15.html Elsmar Cove Quality Forum+8ASTM International | ASTM+8FDA Access Data+8
Pouches are a go-to for flexibility and convenience, but they can fail in critical ways—from poor seals to punctures and delamination—that hurt performance and brand reputation. Understanding these failure points
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