In the pharmaceutical and nutritional industries, packaging is more than just a container, it’s a safeguard for product safety, efficacy, and shelf life. As companies increasingly adopt flexible packaging for its convenience and sustainability, the challenge lies in ensuring that every pouch, sachet, or bag remains completely leak-free. Even a microscopic defect can compromise product integrity, leading to contamination, instability, or regulatory non-compliance. To address these challenges, manufacturers are turning to advanced Container Closure Integrity Testing (CCIT) solutions such as PTI’s VeriPac FLEX system, a trusted technology for ensuring consistent, reliable results.
Flexible Package Integrity Tpackage sting Challenges
Flexible packaging poses unique challenges for integrity testing. Unlike rigid containers, pouches and sachets are made from pliable materials that can deform under pressure, making traditional test methods inconsistent or unreliable.
Common issues include:
- Variations in headspace that affect test accuracy
- Seal irregularities caused by heat or pressure inconsistencies
- Difficulty detecting micro-leaks that are invisible to the naked eye
- Limitations of destructive testing methods such as blue dye or water bath tests, which are subjective and wasteful
To overcome these limitations, manufacturers are shifting towards deterministic, quantitative, and non-destructive test methods that ensure repeatability and precision—essential for meeting FDA and USP <1207> guidelines.
Package Integrity Testing Using VeriPac FLEX
PTI’s VeriPac FLEX system is a non-destructive vacuum decay leak testing solution designed specifically for flexible packaging applications. It delivers a clear PASS or FAIL result, along with quantitative data that correlates directly to leak rates. The system is known for its high sensitivity, reliability, and ability to test a wide variety of flexible package formats and sizes without the need for changeovers or adjustments.
What sets the VeriPac FLEX apart is its flexible membrane test chamber that adapts to the shape of each package, preventing stress or damage to delicate film materials. The technology supports multiple chamber configurations to suit different applications, from the Integrated Flexible Chamber (IFC) for small sachets and stick packs to the Drawer Style (D-Series) chambers for medium and large pouches. For bulk products or special packaging, PTI also offers customized solutions.
Recognized by the FDA and compliant with ISO 11607, the VeriPac FLEX offers manufacturers a robust, regulatory-approved package integrity testing method. It simplifies validation, supports high-throughput testing, and eliminates the waste associated with destructive methods.
Benefits of VeriPac FLEX
Implementing VeriPac FLEX technology brings measurable benefits across production, quality, and sustainability goals:
- Deterministic and quantitative testing – Provides clear, data-driven results
- Non-destructive and non-subjective – No product loss or operator bias
- Multiple packages tested simultaneously – Enhances throughput and efficiency
- Rapid return on investment – Reduces waste, labor, and rework costs
- Supports zero-waste initiatives – Aligns with sustainability objectives
- Simplifies validation and inspection – Streamlined process for quality assurance
Conclusion
Flexible packaging may be versatile, but maintaining its integrity demands uncompromising precision. PTI’s VeriPac FLEX system ensures that pharmaceutical and nutritional products reach consumers safely and without contamination. By replacing outdated, destructive methods with a proven vacuum decay technology, manufacturers can achieve true confidence in their packaging process, ensuring every delivery remains leak-free, compliant, and reliable.