The document outlines a presentation by Mr. Rohit Chawla on packaging testing and hygiene management for food factories, emphasizing the importance of quality packaging in preserving and promoting products. It discusses various testing methods for packaging materials and their significance in ensuring product integrity, safety, and compliance with international standards. Additionally, it highlights common packaging issues and the role of packaging in preventing food wastage and contamination.

1. PACKAGE TESTING AND
HYGIENIC MANAGEMENT
FOR FOOD FACTORY
3RD APRIL 2018
TULIP SEMINAR ROOM, RAMA GARDENS HOTEL, BANGKOK

2. PACKAGING TESTING
METHODS & EQUIPMENTS
Presentation By :
Mr. Rohit Chawla (General Manager)
Test Techno Consultants (PackTest), India.

3. Packaging Quality Advisors
We can help you :
1) Understand
2) Improve
Packaging

4. Machine = Machine
Machine + Knowledge = Solution

5. ABOUT US
• Test Techno Consultants (PackTest) was founded in 1989.
• Manufacturer of Packaging Quality Testing Equipment
• Confirm to major International Standards (ISO / ASTM / TAPPI)
• Confirms to requirements of US Food & Drug Administration (US-FDA)
• Used by all Major Multi-National Companies.
• Factory in INDIA.
• Export to 35+ countries

7. WHAT IS PACKAGING ?
Packaging is the science, art and technology
of enclosing or protecting products
for distribution, storage, sale, and use.

8. 3 P’S OF PACKAGING :

9. Protect:
All packaging should be designed to protect the product from the point of
production through to the point of use, helping to maintain the product in its
original condition. It should aid the distribution and storage of the product.

10. Preserve:
Packaging should assist in the preservation of the product, keeping both liquids
and solids fresh and suitable for use. According to World Health Organisation
statistics, food wastage in the third world can be as high as 50%, whilst in
developed economies as low as 3%. Much of this difference is due to good
quality packaging.
Freshness
+
Nutrition

11. Promote:
Packaging should also aid the promotion of the product by helping to establish
brand recognition and play its role in establishing brand loyalty.

12. Legal Requirement:
It is also typically required to convey instructions for the product, as well as
legal requirements such as warnings, and content ingredients.

13. When and Why to Test a
packaging:
When :
• New packaging design
• Revision to a current design, or
• Change in the packaging material or supplier.
Why :
• Testing a new packaging design before putting it up for full
scale manufacturing can save a lot of
• time
• money and

14. Bigger Loss to
Company NAME / IMAGE
Poor Quality Packaging =
Big Loss to
Company MONEY

15. BASIC PACKAGING MATERIALS
Paper Film Foil Labels

16. GSM TEST (GRAMMAGE)
Applicable to Paper

17. THICKNESS
TEST
Dead Weight
Uniform
Contact Pressure
Applicable to Paper,
Film, Foil, Labels, etc

18. PROBLEM :
PROTECT PRODUCT
FROM OXYGEN
AND MOISTURE

19. PROBLEM : PINHOLES
• Aluminum Foil = GOOD Barrier (Oxygen & Moisture)
• Aluminum Foil with Pinhole = POOR Barrier
Your
Pack

20. Foil Thickness (µm) Average Maximum
7 423 1584
9 211 1056
13 85 528
18 21 106
25 0 0
Source : “The Impact of Foil Pinholes and Flex Cracks on the Moisture and Oxygen Barrier of Flexible Packaging” by Lee Murray of Alcan Pkg
Foil Thickness (µm) Typical Pinhole / Sq Mtr.
11 60
14 40
18 30
20 20
> 25 0
Indian Standards :15392-2003
Maximum Allowable Pinhole Count in One Square Meter of Aluminum Foil

21. PINHOLE TESTER
(LIGHT BOX)
Applicable to Foil and Foil Laminates

23. PROBLEM : PERMEATION

24. WVTR (FILM) OTR (FILM) OTR (BOTTLE)
MoconSystechMocon
---------
Systech
Applicable to
Film and Bottles

25. OTR (FILM) OTR (BOTTLE)
Applicable to
Film, PET Bottles

26. PROBLEM :
DELAMINATION

27. LAMINATE = MULTIPLE LAYERS

28. PEEL STRENGTH TESTER Applicable to
Laminates

30. PROBLEM :
FRICTION

33. COEFFICIENT OF FRICTION
COF < 0.25 LOW COF, HIGH-SLIP
COF > 0.45 HIGH COF, LOW-SLIP
Applicable to Paper, Films and Laminates

35. PROBLEM : PRINT QUALITY DEFECTS
Most Common : Scratches & Scuffs

36. Good Quality Print =
Good Substrate (Paper, Film, Foil, etc)
Good Ink
Good Process (Machine, Handling, etc)
Good Curing (If using varnish)
Good Time (Drying)

37. When does Scuffing damage happen ?

38. INK RUB TEST / SCUFF TEST
Applicable to Paper, Film, Foil, Labels…

40. PRIMARY PACKAGING
POUCHES, BOTTLES,
TRAYS, JARS…

41. TYPES OF POUCH (BASED ON SEAL TYPE)

42. PROBLEM : SEAL QUALITY
Poor Seal =
Leakage, Contamination, etc
Good Seal = Good Pouch

43. SEAL STRENGTH TEST Applicable to
Pouches

44. Cups & Trays too
Lid Peel Test

46. PROBLEM : SEAL INTEGRITY

47. POUCH COMPRESSION TEST
Applicable to :
Liquid Product / Water Filled
Seal Integrity
Find Weakest Spot

48. Static Load Burst Test
Pouches must withstand a force of 7.5 kg for 15 mm
of internal seal length (perimeter).
Applied for 15 seconds
Press + Hold

49. Minimum Force =
( 2 x L ) + ( 2 x W ) x 7.5 Kgf
15
Minimum Force =
( L + W ) Kgf
Eg. If your pouch size is 200x150mm
Then Minimum force is 200 + 150 ( L + W ) Kgf
= 350 Kgf
(applied for 15 seconds)

51. POUCH BURST TEST
INFLATION BURST TEST / BALLOON BURST TEST

52. POUCH BURST TEST / BALLOON BURST TEST
Seal Integrity
Find
Weak
Spot
Applicable to Pouches

53. Internal Burst Test
Pouches must withstand a minimum pressure of 140
kPa (20 psig) before retorting and 105 kPa (15 psig)
after retorting.
Dynamic Burst Test : Till actual burst.
Static Burst Test : Applied for 30 seconds

55. LEAKAGE TEST (VACUUM)
Detect :
1) Pinholes
2) Weak Seals
3) Capillaries
4) Other Defects
Seal Integrity
Applicable to Pouches,
Cups, Trays, Bottles, Jars, Cans

56. 2 Types of Test :
DRY TEST WET TEST
Package has Liquid Package has Air
Tank is Dry (No Water) Tank has Water
Product will come out from leak point Air Bubbles will be seen from leak point
Leakage = Product Contamination
Leakage = Area Contamination

59. PROBLEM : RANCIDITY / LOW SHELF LIFE
+ =
In our food

60. Effects of Rancidity
Bad Smell Bad Taste
Low Shelf Life

61. Pouch with Normal Air
Oil + Oxygen = Oxidation
Oxidation = Low Shelf Life
20.9% O2
20.9% O2

62. Pouch with Modified Atmosphere
Oil + Oxygen = Oxidation
Oxidation = Low Shelf Life
O2
O2
O2
O2 O2
Flush with Nitrogen
to displace OxygenN2N2
N2 N2
N2 Less Less
Less Better
XXX

63. HEADSPACE OXYGEN ANALYSER
Cheap
<50ml
20 Sec
HA One and One+
Applicable to Pouches

64. HEADSPACE OXYGEN ANALYSER
Measure in Gas or Liquid
< 0.1 ml
≈2-3 Sec
Microx
Product
Oxygen too

65. HEADSPACE OXYGEN ANALYSER
Measure O2 and CO2
< 2 ml
≈2-3 Sec
OxyBaby

67. PROBLEM : BOTTLE IS TOO TIGHT OR LOOSE

68. Too Tight Difficult to open
Consumer unhappy

69. Too Loose
- Spillage
- Leakage
- Contamination
Consumer
unhappy

70. In pharmaceuticals, it is even more critical
Too Tight Too Loose

71. TORQUE TEST OF BOTTLE/CAPS
Rotational Force
required to Open / Close
a Cap from the Bottle
is called as TORQUE
Opening Torque
Closing Torque

73. PROBLEM :
POORLY
FORMED BOTTLE

74. BOTTLE WALL THICKNESS
Not Safe
Not Accurate
Time Wastage

75. BOTTLE WALL THICKNESS GAUGE
Safe No Cutting Quick More Accurate

77. TOP LOAD / COMPRESSION STRENGTH OF BOTTLES
How much load can
a bottle take ?
Strong Bottle = Good Bottle

78. - Filling
- Capping
Bottles are subjected to loads :
- Stacking (Warehouse or Store)
When does it happen ?

79. Top Load Test help to :
Identify Best Design
Optimize cost
Without Quality Loss

81. SECONDARY
PACKAGING
CORRUGATED
CARTONS

82. PROBLEM : MOISTURE

83. EFFECTS OF MOISTURE
• High moisture causes loss in strength of
corrugated cartons (compression strength)
• Low Moisture also causes loss in strength of
corrugated cartons (cracking)
• High moisture created breeding ground
from Bacteria and Fungi
• Can lead to Product Contamination

84. MOISTURE TEST
Hot Air Oven
(Loss On Drying)
Instant Moisture Meters
(Electrical Resistance)

85. Primary Purpose
of a
Corrugated Carton
PROTECT

86. Failure to Protect

87. BURSTING STRENGTH TEST
High BS = Good Board ≠ Good Box

89. BOX COMPRESSION STRENGTH TEST / TOP LOAD TEST
High BCT
= Good Box
Most Important
Test for a
Corrugated Box
Compression Strength = Stacking Load x Safety Factor

90. Compression Strength =
Stacking Load x Safety Factor

92. PROBLEM = TRANSIT DAMAGE
Transport Vibrations
Mis-Handling

93. • Leakage
• Spillage
• Damaged Product

94. VIBRATION TEST
(TRANSPORT SIMULATION)
Vibration Test ≠ Box Test
Vibration Test = Content Test

96. TRANSPORT
DATA LOGGER
Measures
• Shock
• Temperature
• Humidity
• Atmospheric Pressure
Date & Time Stamp

97. DROP TEST
Simulate Mis-handling

99. Food Packaging Testing

100. Food Texture Analyser
- Softness
- Hardness
- Crispiness
- Crunchiness
- Sponginess
- Springiness
- Gel Cohesion

103. www.PackTest.com
Thank you for your time