| Visual and workmanship | Visual inspection under suitable lighting; magnification where needed | Contamination, cracks, pinholes, burrs, delamination, wrinkles, print defects, and workmanship | Films, paperboard, glass, metal cans, closures, and finished packs | Define defect categories, sample size, lighting, and acceptance criteria before inspection. |
| Dimensions and thickness | Calipers, micrometers, gauges, and agreed measurement procedures | Length, width, diameter, wall thickness, film thickness, and closure dimensions | Incoming packaging materials and packaging components | Use calibrated instruments and specify measurement locations and tolerances. |
| Seal strength and integrity | Seal-strength testing; dye penetration, bubble emission, or vacuum-decay testing as appropriate | Seal force, channel leaks, and package integrity under defined test conditions | Pouches, lidded trays, sachets, and other heat-sealed packs | Choose a method suited to the package structure; destructive tests may require separate samples. |
| Material composition and food-contact compliance | Document review and, where required, laboratory migration or chemical testing | Declared material structure and compliance with relevant food-contact requirements | Plastic, paper, coatings, adhesives, inks, and multilayer materials | Requirements depend on market, food type, contact time, and temperature. Confirm the applicable rules with a qualified laboratory or regulatory specialist. |
| Barrier performance | Water-vapor transmission or oxygen-transmission testing | Moisture and oxygen transmission through a material under specified conditions | Flexible films and other barrier packaging for moisture- or oxygen-sensitive foods | Results depend on temperature, humidity, test setup, and specimen preparation; compare like-for-like conditions. |
| Print and labeling | Artwork comparison, legibility review, barcode verification, and rub or adhesion checks when specified | Text, color, placement, barcode readability, and print durability | Printed films, cartons, labels, and finished consumer packs | Check against approved artwork and the labeling rules of the intended sales market. |
| Net quantity and fill level | Checkweighing or weighing samples using a calibrated scale | Product weight or volume against the declared quantity and agreed limits | Filled and sealed food products | Account for tare weight and apply the legal metrology rules relevant to the destination market. |
| Foreign-body detection | Metal detection or X-ray inspection on the production line | Detectable metal contaminants or certain dense foreign materials, depending on the system and product | Finished products where the hazard analysis identifies a need for detection controls | Performance varies with product, package, contaminant type, and equipment settings; validate detection limits on the actual line. |
| Closure and package fit | Torque measurement, fit checks, and leak testing where applicable | Closure application, cap fit, and evidence of leakage or poor sealing | Bottles, jars, screw caps, and other reclosable packs | Set limits based on the container-and-closure system and the product’s storage and transport needs. |
| Carton and transport durability | Compression, drop, or vibration testing using an agreed protocol | Resistance to stacking, handling, and distribution stresses | Secondary packaging and packed shipments | Choose test conditions to reflect the intended packaging configuration and distribution route. |