Evaluating CO₂ Tracer Gas Ingress for Integrity Assessment of Flexible Film Packaging
Summary
This case study evaluates laser-based Headspace Analysis (HSA) and CO₂ tracer gas ingress as a deterministic, non-destructive method for assessing the Container Closure Integrity (CCI) of flexible film packaging. By exposing bags with laser-drilled micro-defects to a CO₂ environment under overpressure, researchers successfully measured gas accumulation to distinguish between actual seal leaks and natural material permeation in semi-permeable systems. The study demonstrates a clear correlation between defect size and gas concentration over time, showing that even minute 10 µm and 20 µm defects can be objectively identified and separated from background permeation levels.
Technology
The Gasporox sensors and instruments are built on more than 25 years of development and refinement in industrial laser-based gas measurement. The system uses Tunable Diode Laser Absorption Spectroscopy (TDLAS), a highly reliable and precise method for non-destructive headspace gas analysis.
Developed by Gasporox in collaboration with its technology partners, this laser sensor technology is widely used in demanding industries such as pharmaceuticals, petrochemicals, and energy.
Gasporox’s laser-based headspace analysis has been successfully deployed for over a decade in pharmaceutical manufacturing. It is integrated into fully automated inspection systems and benchtop instruments for 100% in-line and laboratory testing of vials, ampoules, and other parenteral packaging formats. The performance and robustness of the system have been validated through extensive real-world use.
