Introduction to Food Packaging Testing 

Today, packaging in the food industry is important because it affects the product’s shelf life, safety, and whether regulators approve it. Therefore, food packaging testing is now a necessary step in manufacturing. 

The European Food Safety Authority (EFSA) reports that more than 4,000 chemical substances are in food-contact materials. If these are not tested properly, they could end up in food, harming people and causing expensive recalls. 

Manufacturers use different tests to check how well a product can withstand physical forces, changes in chemicals, and stress from the environment. They help companies comply with industry rules and also encourage new ideas for sustainable packaging. 

In the next sections, we’ll look at the main goals of packaging testing in today’s competitive market, examine its main types, review the key standards and rules, and talk about how manufacturers can use data to enhance their products and build trust with consumers.

Key Objectives of Food Packaging Testing 

The main reasons for testing food packaging are to guarantee safety, preserve quality, and meet all required regulations. All these goals are linked, helping to maintain the integrity of the food supply chain.

1. Ensuring Product Safety: 

Packaging is the first barrier that keeps outside contaminants away. Testing guarantees that the packaging does not release harmful chemicals into the food, thus protecting consumers. This means testing for heavy metals, restricted substances, and other dangerous materials.

2. Maintaining Product Quality: 

Besides safety, packaging is responsible for keeping the food fresh, tasty, and nutritious. Testing checks the seal, how much moisture and oxygen can pass through, and how well the packaging protects the food during its shelf life.

3. Achieving Regulatory Compliance: 

Every region has its own set of rules for food contact materials. Testing ensures that the packaging follows these standards, which helps with easy distribution in different markets. It is often necessary to comply with ASTM International and the International Safe Transit Association.

4. Supporting Sustainable Practices: 

As the industry moves towards using less waste, testing guarantees that sustainable packaging is both safe and effective. It requires checking how biodegradable materials interact with food products. When manufacturers focus on these objectives, their packaging will meet industry rules, please consumers, and be environmentally friendly.

Main Categories of Food Packaging Testing Methods 

When we discuss food packaging testing and lab testing, we mean a variety of tests that work together to guarantee the packaging is safe, effective, and meets all requirements from start to finish. The type of testing used depends on the packaging of the product, the conditions it might experience, and the rules set by different countries. Let’s take a closer look at the main categories.

Physical Performance Testing 

During physical performance testing, packaging materials are tested to see how they handle the mechanical stresses they experience during all stages of use. They are necessary to keep packaging safe and effective in protecting the product throughout the supply chain.

• Compression Testing: 

The test checks if a package can withstand being pushed from above without breaking or bending. It is most important for products that are stored or transported in stacks. If compression fails, it can lead to packaging problems, unsafe food, and losses in logistics. Good compression resistance is necessary to keep the structure strong and to shield the contents from outside pressures. 

• Tensile Strength Testing: 

Tensile testing determines the force needed to separate a packaging material. Films, laminates, and flexible packaging used in automated filling or sealing need to be especially important. Strong tensile strength prevents the packaging from tearing and allows it to keep its shape and work properly under usual conditions.

• Impact Testing: 

Impact testing checks how packaging handles sudden shocks or drops, which often happen during handling and transport. The test helps avoid damage, leaks, or changes in shape for food products, mainly for fragile items and containers with liquid inside. Having good impact resistance helps cut down on waste and protects consumers. 

• Seal Integrity Testing: 

Seal integrity testing is done to check that the closures are not leaking when exposed to external forces. A good seal is necessary to stop contamination, keep food fresh, and maintain the quality of materials that come into contact with food. If seals are not strong enough, they can allow microbes to enter and cause the food to spoil.

Any packaging testing process relies on these physical tests. They supply manufacturers with important information to improve packaging, pick the right materials, and comply with industry standards for safe products. 

Environmental Resistance Testing 

This type of testing deals with the packaging of food products under various conditions related to environmental factors and how they affect the product during its entire life cycle. As in all processes, packaging is meant to shield its contents from external temperature, humidity, and physical stress, as seen from factory storage to international shipping. These tests guarantee the stability and safety of both the product and its packaging up until consumption.

• Temperature and Humidity Exposure: 

This approach analyzes the mechanical stability and functionality of packaging under extreme or unexpected climate changes. Elevated temperatures could cause materials to soften and warp, adhesives to loosen, and seals to break. Cold temperatures could lead to brittleness and cracking of materials. Humidity may also lead to the degradation of paper packaging and seals. Testing ensures that the packaging can withstand a wide range of geographic and seasonal changes without losing its protective qualities. 

• Vibration Testing: 

Vibration replicates the movements and shocks sustained during transport by road, rail, sea, or air. Continued exposure to such vibrations may lead to material fatigue, seal failure, or shifting of the internal product, leading to damage. Identifying weak points within the packaging before distribution enables manufacturers to enhance packaging design and mitigate potential damage throughout the supply chain. 

• Shelf Life Studies: 

Shelf life evaluation checks if the packaging keeps its shape and protects the product as it is stored normally. You should watch for any changes in the packaging’s look, strength, and ability to keep the product safe. These studies are often related to food contact materials testing and help determine how fresh the product will be, identify any packaging problems, and reduce waste. 

Environmental resistance testing helps ensure that products are safe, their packaging is reliable, and consumers trust them. Because there is more demand for efficient and sustainable packaging, manufacturers must ensure their packaging is dependable in all conditions and does not affect the food or its quality. 

Chemical and Migration Testing 

The chemical and migration tests focus on the boundaries of the interaction between the food and the materials used to package it. The objective is to prevent the transfer of any hazardous materials from the food packaging to the contents within during regular use. These tests are essential for public health, compliance with applicable regulations, and protection of consumers. 

• Migration Testing:  

The migration testing determines the possible contamination of food by chemicals present in a container. Such chemicals can be made of plastics, solvents, monomers, or manufacturing residues. The testing is done under controlled conditions that mimic real-life situations of storage or heating. It checks if the migration levels are within the limits acceptable for public health and food safety guidelines. This is particularly important in food contact materials testing, where thorough exposure to heat over a long period has the potential to increase the rate of migration of chemicals. 

• Restricted Substance Testing: 

This test focuses on the restriction of use or outright ban of chemicals within the packaging materials. Some of the commonly controlled materials due to moderate to high health risks, such as heavy metals, phthalates, and bisphenol A (BPA). The testing confirms that such materials are not present, or if they are, then only in legally permissible limits. For manufacturers, this aids their business strategy in protecting them from being accused of breaching regulatory policies and defending their brand image in the current market. 

• Compatibility Testing: 

This method assesses if the food and packaging will interact over a given duration. For instance, some high-fat or acidic foods could be destructive to some plastics or adhesives and cause contamination or change some sensory attributes of the food. Compatibility testing helps understand the effectiveness of the packaging material, while direct contact with certain food types assists in selection for specifically designed package materials. 

Safety assessment does not end at chemical testing; it also encompasses growing international concern about the transparency of the supply chain and environmental responsibility. The introduction of new materials and sustainable concepts for packaging is usually safeguarded by vigorous testing to ensure innovation does not harm public health. 

Barrier Property Testing 

Barrier property testing is very critical in determining the efficiency of a given packaging material in protecting food from exposure to oxygen, moisture, and gases that may affect their quality, freshness, or safety. Proper barrier performance ensures increased shelf life, product integrity, and helps fulfill requirements for a broad array of food products. 

• Oxygen Transmission Rate (OTR): 

OTR testing evaluates the extent of oxygen permeation in each specific packaging material. Some of the factors to consider in perishables, such as snacks, ready-to-eat meals, coffee, dairy, etc., are how quickly oxygen exposure can accelerate oxidation, cause degradation, and even alter color. For such businesses or products that are oxygen sensitive, low OTR values are essential to maintain color, flavor, and freshness. Taking accurate measurements helps in choosing opposing materials that need the right barrier level. 

• Moisture Vapor Transmission Rate (MVTR): 

MVTR testing focuses on how well a packaging seals moisture inside or outside of the package. This is crucial for dry goods like cereals, powders, and dehydrated foods, where moisture can clump, promote microbial growth, or cause textural losses. In the same way, some products require a controlled loss of moisture to maintain quality. Manufacturers can enhance product stability under varying environmental exposure, as well as during prolonged storage or shipment, by knowing the material’s MVTR. 

Barrier property testing is now at the heart of food packaging testing because of the growing interest in bio-based and sustainable food packaging. Newer materials are often bio-based, which requires proving that they offer at least the same level of protection as conventional plastics to maintain safety and quality within the supply chain. Besides, consistent barrier performance aids in meeting the required guidelines that govern barriers and helps strengthen market trust with end consumers and retailers. 

Testing Standards and Compliance for Food Packaging 

To make food packaging testing effective, manufacturers should use recognized testing methods and obey all necessary safety, performance, and consumer safety guidelines for consumer goods. They help direct the testing and also decide if a packaging solution is ready for use in the market.

Many international organizations are responsible for setting these standards. ASTM International, ISO, and the International Safe Transit Association have established recognized methods for testing packaging under mechanical, chemical, and environmental conditions. Using these methods guarantees that test results are the same and can be compared for various materials and products. 

The U.S. Food and Drug Administration (FDA) and the European Food Safety Agency (EFSA) are responsible for setting rules on how much chemical can be used in food contact materials. As an example, migration testing is necessary to ensure that heavy metals, solvents, or plasticizers do not end up in the food at dangerous levels. 

Following these safety regulations is important for the law, but it also helps protect consumers, people’s health, and the environment. Often, if packaging does not meet the necessary standards, it can result in delays in launching products, removing them from the market, or facing legal consequences. 

Having a good compliance record helps a business gain trust from all partners in the supply chain. It also helps earn consumer trust, mainly in industries where the condition of the packaging determines both the product’s quality and how long it can be stored. For this reason, including compliance-driven testing in the product development process is essential, not something to consider only after the product is finished. 

How to Interpret and Act on Food Packaging Testing Results 

Reading the numbers from food packaging tests is important, but you should also understand what they say about the product’s safety, how long it can be kept, and if it meets regulations. Migration limits, oxygen transmission rate (OTR), and moisture vapor transmission rate (MVTR) are three indicators that usually matter a lot. 

If a migration test is above the legal limits, it may suggest a risk to human health and should be checked right away. If the OTR is higher than expected, it may cause food products that need oxygen to spoil more quickly. In addition, high MVTR can result in food becoming spoiled or having a different texture. The way these figures are used depends on the food, its packaging, and the conditions it will be distributed in. 

If test results are below standard, manufacturers should check if the problem is with the materials, the packaging, or the way the product is made. Often, the problem can be solved by using a different barrier material, making the seal stronger, or changing the thickness of the packaging. Nevertheless, design changes should be tested thoroughly before being used. 

Optimize Packaging Performance with Reliable Machinery 

A good packaging system begins with careful and precise work at the production line, not just with passing lab tests. The quality of equipment is directly linked to the results of seal integrity, oxygen transmission rate (OTR), and migration limits. If your machinery is not performing well, even the best packaging materials might not pass tough tests. 

Levapack offers fully automated packaging systems for the food industry. We have been making high-precision filling machines, canning machines, sealing machines, capping machines, and labeling machines for more than 18 years. We use 304/316 food-grade stainless steel for our equipment and add components from Siemens, SMC, and Schneider to ensure it is stable, hygienic, and performs the same way every time in an industrial setting. 

If you are a food brand or an OEM/ODM partner, Levapack can provide you with custom packaging, flexible designs, and worldwide support. We can use a variety of containers and materials with our machines, and we test their quality by checking the strength of the seal and aging them for 36 hours. 

If you want to improve packaging and avoid expensive testing failures, the right equipment is key. Contact Levapack and find out about automation solutions that match your product, the scale of your production, and your testing requirements. 

Common Challenges and How to Avoid Testing Failures 

Even seasoned manufacturers in food packaging testing can run into problems that affect accuracy or compliance. They are often caused by new regulations, differences in materials, or problems with operations. If these issues are handled early, both failures and the overall quality of the product can be improved. The table below lists common problems and useful ways to address them: 

Future Trends in Food Packaging Testing 

When the food industry changes, the standards for food packaging testing also change. Innovation is now leading to changes in three important areas: smart technologies, sustainable materials, and quality control based on data. 

Smart Packaging and Digital Testing Needs 

Smart packaging is now being used in practice. More and more, high-value food products are using embedded sensors, freshness indicators, and temperature trackers. Because of these innovations, new types of packaging tests are needed, such as checking digital compatibility and sensor reliability. Packaging should keep food safe and also allow for real-time data and safety monitoring. 

Sustainable Materials Requiring New Validation Methods 

Sustainability is still a main concern, and manufacturers are investigating biodegradable films, recyclable polymers, and plant-based sustainable packaging solutions. Still, these methods introduce their own set of testing problems. They should be approved for use with food, last a reasonable amount of time, and work well in different transport situations. For this reason, packaging testing is now designed to check both how well it works and if it is environmentally safe.

AI and Data Analytics Enhancing Quality Assurance 

Machine learning is helping manufacturers rethink how they evaluate their packaging. AI systems use large amounts of test data to find patterns of failure, predict how the system will perform over time, and recommend ways to improve the design. Using data in this way helps speed up testing, shorten the time to release new products, and maintain a high level of safety compliance. 

They suggest that companies are moving from reactive quality control to using technology to plan their packaging. Those who update their testing methods can more easily meet regulations, ensure their products are safe, and stay ahead in a fast-changing market. 

Final Thought 

Food packaging testing is necessary for safety and quality, not only for meeting regulations. By testing for durability, chemical safety, and migration limits, packaging materials are proven to work well in all parts of the supply chain and different environments. 

Testing at the beginning of packaging design helps avoid product failures, makes recalls less likely, and improves how consumers view the product. It also helps companies follow international standards from ASTM International and the International Safe Transit Association, which supports compliance with regulations worldwide. 

When packaging technologies change, testing should also change to meet specific requirements. No matter if you are using sustainable materials or smart packaging, a reliable and planned testing process is necessary. When you include it in your quality assurance process, you help protect your product and support your brand’s and company’s ongoing success.