・Insufficient packaging（Poor barrier propertiesImproper specifications, incorrect material selection, poor seams and seals, etc. can cause certain compounds to penetrate at a faster rate than expected shelf life, leading to premature deterioration of the product. The impact of insufficient packaging may range from product complaints to returnsExtending to warranty expiration or triggering legal actionLawsuits can lead to economic losses and damage to brand reputation for businesses.

・Excessive packaging may result in serious waste of funds and material resources. Many times, due to a lack of product knowledge, companies will choose the best packaging they can find to prevent insufficient packaging. A common example is the use of thicker or multi-layer materials, which can lead to increased costs. For large-scale production enterprises, the additional costs are enormous. If appropriate testing plans are implemented during the development process, a significant amount of money can be saved by avoiding excessive packaging.

As shown in the figure, at both ends of the curve, products with insufficient packaging will deteriorate, leading to an increase in complaints, warranty costs, waste, and negative impact on the environment;Excessive packaging can lead to excessive use of materials, which not only increases costs but also imposes a burden on environmental safety as more plastic is dumped in landfills.The intersection in the figure shows an optimized packaging system with effective marketing, product protection, and cost advantages.To optimize packaging design, the key is to understand the permeability characteristics of the packaging to avoid over packaging and under packaging.

MOCON recommends the following methods for determining optimized packaging design:

1. Determine the tolerance level of the product

The key element of successful packaging design is to determine the maximum degree of degradation allowed for the product due to exposure to permeable gases such as oxygen and water vapor, in order to meet the expected shelf life goals. this kind ofdegradePossible occurrence due to gas entering and exiting the packaging. In addition, other gases such as carbon dioxide, odors, and fragrances should also be considered. The low tolerance level of the product determines the allowable gas permeability requirement for packaging.

2. Determine alternative barrier materials

To determine whether the material meets the requirements, a comprehensive testing procedure should be conducted. First, toalternativePerform gas permeability testing on the sheet to confirm the data provided by the supplier and narrow down the candidate range. Ensure correct results through repeated testing. During these tests,alternativeThe material must be tested under appropriate testing conditions (temperature and relative humidity) to reflect the actual situation.

3. Design preliminary packaging system

Subsequently, calculate using theoretical packaging dimensionsMatchProduct requirements and alternative materials to determine whether the materials can meet the shelf life requirementsRequest or determine which material can provide a specific shelf life for a given packaging size. MOCON has concluded through case studies that this step is necessary for selecting materials correctly.

4. Test the complete packaging

Next, alternative materials must be used to create packaging prototypes that conform to the expected packaging design. Then, preliminary packaging prototypes with specific packaging dimensions, functional characteristics, and sealing structures are tested to determine the overall barrier performance of the packaging.

5. Adjust the packaging system for optimization

To optimize packaging design, it is usually necessary to repeat steps 3 and 4 until the optimal packaging system is achieved. According to the nature of the product, there areAdditional methods such as Modified Atmosphere Packaging (MAP) will be introduced to extend the shelf life of products without increasing the thickness of packaging materials.

6. Fast and accurate testing methods

MOCON's penetration analyzer can provide accurate test results within hours or days, helping companies make quick adjustments and improvements,Greatly improved research and development efficiency. Overall, fast and accurate testing methods will bring confidence and help achieve more success.

The role of penetration testing in the packaging design process is a very valuable step, which effectively helps companies avoid the risk of expensive over packaging or inadequate packaging. Only through penetration testing can packaging materials be designed and validated to provide necessary protection for the expected shelf life of enterprise products and minimize the impact of materials on the environment.