Common Problems Faced in Testing Projects

Paper and packaging testing projects frequently encounter several recurring challenges that compromise product protection and compliance. The use of substandard materials leading to premature failures and packaging defects remains widespread, particularly when suppliers substitute approved grades with cheaper alternatives. Reliance on untested packaging without verified performance data creates significant liability risks and unpredictable field behavior. Inadequate understanding of distribution hazards—such as drop height, compression load, vibration, and humidity—causes designers to misinterpret standard test results for real-world applications. Non-compliance with evolving standards results in regulatory rejection, costly redesigns, and project delays. Poor documentation of material specifications and test traceability undermines certification efforts and complicates regulatory audits. Addressing these problems requires rigorous supplier verification, accredited testing partnerships, and comprehensive quality assurance protocols from project inception through completion.

Key Parameters Evaluated During Testing

Paper and packaging testing evaluates several critical performance parameters that determine material safety and compliance:

• Compression Strength (ASTM D642 / TAPPI T804) — Measures the ability of shipping containers to withstand stacking loads during storage and transit.
• Tensile Strength (TAPPI T494 / ISO 1924) — Evaluates the force required to break paper or paperboard under tension, indicating structural integrity.
• Tear Resistance (TAPPI T414 / ASTM D689) — Determines resistance to tearing, critical for handling and converting operations.
• Burst Strength (TAPPI T403 / ASTM D774) — Assesses resistance to rupture under internal pressure, indicating material toughness.
• Puncture Resistance (ASTM D781 / TAPPI T803) — Measures resistance to penetration by sharp objects during handling and transit.
• Moisture Vapor Transmission Rate (MVTR) — Quantifies barrier performance against moisture ingress, critical for food and pharmaceutical packaging.
• Cobb Value (TAPPI T441) — Determines water absorptiveness of paper and paperboard, indicating resistance to liquid penetration.
• Printability and Surface Properties — Evaluates ink adhesion, gloss, and surface smoothness for branding and labelling applications.

These parameters collectively provide a comprehensive packaging performance profile, enabling informed material selection and regulatory compliance verification.

Types of Materials Commonly Tested

Paper and packaging testing applies to a diverse range of materials, each presenting unique performance characteristics:

• Paper and paperboard: Kraft paper, linerboard, folding carton board, and coated papers used in primary and secondary packaging.
• Corrugated board: Single-wall, double-wall, and triple-wall corrugated sheets used in shipping containers and protective packaging.
• Flexible films and laminates: PE, PP, PET, and metallized films used in pouches, bags, and wrappers.
• Labels and adhesives: Pressure-sensitive labels, wet-glue labels, and adhesive systems requiring peel and shear strength evaluation.
• Closures and seals: Caps, lids, tamper-evident seals, and induction seals requiring seal integrity and torque testing.
• Food-contact packaging: Trays, cups, wrappers, and containers requiring migration and barrier testing.
• Pharmaceutical packaging: Blister packs, sachets, vials, and cartons requiring child-resistance and moisture barrier verification.
• E-commerce packaging: Mailers, boxes, and protective inserts requiring drop and compression resistance.

Risks of Using Untested Materials

Using untested packaging in product applications introduces serious safety, legal, and financial risks that can compromise entire product lines:

• Product damage during transit due to unknown compression or puncture resistance, causing customer dissatisfaction and returns.
• Moisture and oxygen ingress without verified barrier ratings, leading to spoilage, staleness, or contamination.
• Regulatory non-compliance leading to product rejection, costly recalls, or legal liability for responsible parties.
• Contamination and toxicity from chemical migration or additive leaching, endangering consumer health in food and pharmaceutical applications.
• Accelerated deterioration and high replacement costs from substandard materials that fail prematurely.
• Insurance and liability exposure from unverified performance claims, potentially voiding coverage and exposing stakeholders to litigation.
• Brand reputation damage from repeated product failures and negative customer experiences.

These cumulative risks make certified paper and packaging testing essential for responsible material selection.

How METS Laboratories Supports Testing

METS Laboratories provides comprehensive paper and packaging testing services covering compression strength, tensile and tear resistance, burst and puncture resistance, moisture barrier analysis, seal integrity, and transit simulation for paper, paperboard, corrugated, and flexible packaging materials. Their capabilities include testing for compression strength, tensile properties, tear resistance, burst strength, puncture resistance, MVTR, Cobb value, and printability assessment. The laboratory supports paper and packaging testing to ASTM D642, ASTM D4169, TAPPI T494, TAPPI T403, ISO 1924, ISO 2233, and international standards including FDA, EU, USP, and ISTA requirements. METS Laboratories delivers independently verified test data suitable for regulatory submissions, risk assessments, and product certification. With accredited facilities and experienced technical teams, they ensure accurate, reproducible results aligned with global standards. Their end-to-end support helps manufacturers, brand owners, and project teams demonstrate compliance, reduce liability, and deliver safer, more durable packaging with confidence.