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Chevron seals are a type of sealing mechanism used in various packaging applications, known for their distinctive V-shaped or chevron pattern. These seals are often employed in flexible packaging materials like pouches, bags, and sachets. The design of chevron seals allows them to maintain strength and flexibility, even when subjected to stress, and they are widely used in applications that require reliable containment of the product. Traditional testing methods often involve destructive processes or are limited in their ability to detect certain seal defects. However, the move toward non-destructive testing techniques, such as Seal-Scan® airborne ultrasound technology, is transforming the way manufacturers approach seal inspection.

The Need for Precision in Chevron Seal Inspections

Chevron seals are widely used in applications where maintaining airtightness, sterile barrier protection and preventing contamination are priorities, such as in medical devices and pharmaceuticals. Precision in inspecting these seals ensures they function as intended, avoiding issues like leaks or compromised integrity that can lead to product failures or safety concerns. Advanced inspection techniques, such as non-destructive testing and high-resolution imaging, are effective for identifying even the smallest imperfections that might otherwise go unnoticed. Automated systems enhance accuracy and consistency, reducing the likelihood of human error and improving efficiency in quality assurance processes. Ensuring that chevron seals meet stringent standards also supports compliance with industry regulations, safeguarding consumer trust and preventing costly recalls. As packaging and sealing technologies evolve, maintaining precise inspection practices ensures reliable performance, upholds product quality, and aligns with the growing demands for safety and accountability in regulated industries.

Seal Integrity Testing Using Seal Scan® Technology

Ensuring the quality of chevron seals is critical to maintaining the performance and reliability of sealed products. Seal-Scan® systems offer a non-destructive and highly precise solution for assessing seal quality. By leveraging Airborne Ultrasound Technology, these systems detect and analyze defects in pouch seals with exceptional accuracy. This deterministic, quantitative, and high-resolution approach to package integrity testing ensures consistent seal quality by identifying defects and verifying seal integrity.

The technology operates by scanning pouch seals or packaging materials using two focused ultrasonic sensors. As ultrasonic waves pass through single or multi-layered bonded materials, variations in the medium reflect the sound waves, reducing signal strength. The amount of signal transmitted through the seal correlates directly to its quality. Seal-Scan® detects a wide range of defects, including both leaking and non-leaking issues, as well as process-related and random defects. It generates Opto-Acoustic images and detailed statistical analysis using L-Scan and C-Scan modes. L-Scan generates a line graph of seal integrity along the X-axis, simulating online inspection, while C-Scan creates high-resolution ultrasonic images by scanning along both the X and Y axes of the seal area. The technology can be seamlessly integrated into production lines using the Seal-Sensor for 100% on-line defect detection.

Seal Scan Technology Benefits

• Deterministic inspection method producing quantitative results.
• Works for any material and combinations, regardless of color, transparency, print, surface finish and porosity.
• Produces high resolution Opto-Acoustic image of seal.
• Characterizes overall quality and uniformity of the seal.
• ASTM Test Method F3004 and FDA standard for seal quality inspection.

The shift toward non-destructive testing techniques in chevron seal quality control marks a significant advancement in packaging inspection. By adopting methods like Seal-Scan® technology, manufacturers can ensure more accurate and reliable assessments of seal integrity without compromising the packaging. This approach helps streamline production processes, reduce waste, and maintain high-quality standards across industries. As the demand for efficient and precise quality control grows, non-destructive testing will continue to play an increasing role in improving packaging reliability and product safety. By embracing these innovative solutions, manufacturers are better equipped to meet the challenges of modern packaging requirements.

Pharmaceutical products are designed to enhance health and support effective treatment. Ensuring the quality and safety of these products relies on maintaining intact packaging that protects against contamination, moisture, and other external factors. Integrity testing methods, such as Vacuum Decay, helium leak detection, and high voltage leak detection, verify that packaging meets regulatory standards like USP <1207>. These methods identify even the smallest leaks, confirming that containers perform their intended function. Comprehensive integrity testing helps manufacturers achieve compliance, mitigate risks, and ensure product safety and reliability.

VeriPac Delta for Package Integrity Testing

VeriPac Delta is a dual technology non-destructive quantitative test system for pharmaceutical CCI applications. Capable of detecting leak rates as small as 5 microns, depending on package specifications, it provides a non-destructive, quantitative testing solution for pharmaceutical and food applications. It is specifically designed for testing gas leaks in dry product containers, such as lyophilized and powder-filled vials, as well as liquid leaks in liquid-filled vials and prefilled syringes.

The VeriPac Delta employs two primary technologies: Vacuum Decay and Pressure Decay. Vacuum Decay leak testing, based on ASTM F2338-09 and recognized by the FDA as a consensus method, delivers sensitivity down to 5 microns. Pressure Decay testing, compliant with ASTM F2095, achieves similar sensitivity with rapid test cycles of just 10 seconds. Together, these technologies provide precise, efficient, and reliable solutions for comprehensive package integrity assessments.

Technology Overview

The VeriPac Delta connects to a specially engineered test chamber. During testing, vacuum or pressure is applied to the package within the chamber. Using high-resolution absolute transducer technology, the system monitors the applied vacuum or pressure levels and detects changes over a specified test duration. This enables accurate detection of gross and micro leaks. The test cycle completes in a few seconds, delivering objective, non-destructive results that preserve both the product and its packaging.

The sensitivity of the test depends on factors such as transducer capability, package design, test fixture, and key parameters like time and pressure. The VeriPac Delta system can be configured for manual or semi-automatic operation, making it suitable for laboratory offline testing and QA/QC statistical process control.

Benefits of VeriPac Delta Technology

• Non-destructive, non-subjective, no sample preparation
• Deterministic, quantitative test method
• Small footprint and modular portable design
• Defect detection down to 0.2 ccm (5 micron)
• ASTM test method and FDA standard
• High level of sensitivity, repeatability and accuracy

The integrity of pharmaceutical products relies on robust packaging that preserves quality and prevents contamination. The VeriPac Delta is an effective and versatile solution for pharmaceutical package integrity testing. By combining non-destructive methodologies, rapid testing cycles, and exceptional sensitivity, it offers more than just leak detection—it provides a comprehensive approach to safeguarding product integrity. Its adaptability across diverse packaging formats ensures its value in advancing quality assurance processes within the pharmaceutical industry.