1.Products with inflated packaging that show packaging collapse within the shelf life, but no obvious leakage is detected upon visual inspection.
答：
The problem is not always caused by physical leakage. One possibility is that the packaging material has insufficient barrier properties against protective gases such as nitrogen and carbon dioxide, resulting in the slow escape of the gases. Another possibility is that there are minor defects in the packaging's sealing, such as uneven heat sealing strength. For example, the root cause of the collapse of a certain milk powder packaging was the uneven strength at the heat seal (as low as 18N/15mm, while the good areas were 45N/15mm), and leakage occurred at -65kPa during the negative pressure test.
Solution: A systematic test is required to measure the permeability of packaging materials to nitrogen and carbon dioxide, with a particular focus on the barrier properties after being rolled. This is to simulate the loss during transportation. The test can be conducted by the permeability tester GTR(https://www.linktesting.org/3852.html/gas-permeability-tester-gtc-203h/) At the same time, the sealing performance (negative pressure method https://www.linktesting.org/903.html/leakage-tester/) of the finished packaging should be tested, and the stability and uniformity of the heat sealing parameters should be ensured.
2.The packaging bags of frozen foods (such as ice cream) may experience bag cracking or bag rupture either when they are in the frozen state or after thawing.
答：
Ordinary packaging materials will become brittle and lose their flexibility in low-temperature environments. Their resistance to impact and puncture will also decrease. At this point, if they are squeezed by external force or punctured by the contents (such as bone-in meat products), they are very likely to rupture.
Solution: Appropriate materials with excellent low-temperature resistance should be selected, such as formulations with a high content of PE (polyethylene). The impact resistance and cold resistance of the packaging should be tested under freezing conditions, rather than just testing the performance at normal temperatures. The test can be conducted by the falling dart impact tester(https://www.linktesting.org/856.html/ltmc-a-falling-dart-impact-tester/)
3.After the product was transported, the outer box seemed intact, but the internal products (glassware) had been damaged due to shaking and collision.
答：
This is one of the most common problems in e-commerce packaging. The core issue lies in insufficient cushioning and poor product fixation. For instance, the amount of cushioning material (such as bubble wrap) is insufficient, or there is space for movement of the product within the box, causing the vibration and shock during transportation to directly impact the product.
Solution: Implement a "full enclosure" type of cushioning to ensure protection around and above the product. For delicate or fragile items, use custom foam or pearl cotton clips to securely fix the product. The size of the outer box should match the product and the cushioning material, with a buffer space of 1-2 cm reserved.
4.The aseptic packaging of medical devices (such as blister boxes) may develop tiny cracks at the sealing edges after undergoing transportation simulations or aging, resulting in the failure of the aseptic barrier.
答：
The root cause of the problem often lies in the design details. For instance, the width of the sealing edge at the corners of the blister packaging is uneven, creating a "weak point" in terms of mechanics. Additionally, if the heat sealing parameters are only at the "passing" lower limit, the sealing strength is insufficient to withstand transportation vibrations, and it is prone to generating fatigue micro-cracks.
Solution: Optimize the design of the blister box mold to ensure uniform width of the sealing edge and eliminate stress concentration points. Use DOE (experimental design) to find the optimal combination of heat sealing temperature, pressure and time, and establish a stable process window. Additionally, conduct a complete transportation simulation test (such as ASTM D4169) to verify. The test can be conducted by the heat seal tester (https://www.linktesting.org/891.html/heat-seal-tester-lth-h3/)
5.There are spots, scratches on the surface of the packaging film, or the composite layer is delaminated (split), wrinkled, or frayed.
答：
Although these defects do not directly affect the sealing performance, they seriously impact the brand image. For instance, composite white spots may result from insufficient ink coverage, uneven adhesive application, or blocked printing dots. Layer delamination in the composite structure is mostly caused by improper adhesive selection or insufficient curing.
Solution: In the printing process, it is necessary to ensure the ink coverage, control the solvent ratio, and keep the printing plate clean. In the laminating process, select the appropriate adhesive and ensure uniform coating. For the existing scratches, remedial measures such as "room temperature curing" can be adopted.
