Ensuring efficient and timely packaging quality control is essential for any company operating in the cosmetics, pharmaceutical and food sectors. At Eurovetrocap, we are aware that the reliability of a bottle, jar or pump determines not only the safety of the contents, but also the reputation of the brand on the market.
This is why it is important to develop a structured quality control system, which combines inspection procedures, functional tests and international standards such as ISO 2859.
The various aspects of packaging quality control – from knowledge of acceptable quality standards and limits (AQL) to practical tests to verify the airtight seal of the bottle or the resistance of paints – allows to reduce disputes, minimize defects and maintain a constant level of reliability.
The importance of packaging quality control
When we talk about packaging quality control, we refer to a set of procedures and tools that aim to verify the conformity of a product with respect to pre-established criteria in the technical specifications or in the conditions of sale agreed between supplier and customer. No production process is 100% defect-free, the presence of defects in a certain percentage of the batch is physiological; what matters, however, is that the number of defects falls within acceptable limits, defined on the basis of the customer’s real needs, the type of product and industry standards.
At Eurovetrocap, quality management plays a crucial role right from the early stages of design. We offer solutions for primary packaging in glass, plastic and aluminum, intended for fragrances, skincare, make-up, pharma and many other sectors. Each product line has specific characteristics: for example, a perfume bottle must favor the aesthetic aspect and the airtight seal, while a face cream jar must combine functional effectiveness and resistance to various chemical and mechanical stresses.
Packaging quality control is, therefore, an advantage both for the supplier, who reduces the risk of complaints or returns, and for the customer, who can offer reliable products on the market that meet expectations.
ISO 2859 and AQL: what they are and what they are used for
One of the key aspects of quality management is determining how many parts to check and how to judge their suitability. To this end, at an international level, we often rely on the reference standard ISO 2859, a standard that regulates sampling and inspection procedures by attributes, and on the AQL (Acceptable Quality Limit), i.e. the level of acceptable quality.
ISO 2859
Applied in different sectors (cosmetics, pharmaceuticals, food, manufacturing), ISO 2859 guarantees an objective statistical approach, reducing subjectivity in the analysis and providing a solid basis for making decisions on the acceptance or rejection of parts. Defines the number of parts to be inspected in a given batch. It also specifies the acceptance or rejection criteria for that batch, based on the presence of defects within the sample.
AQL (Acceptable Quality Limit)
The AQL (Acceptance Quality Limit) represents the maximum percentage of defects that can be tolerated within a batch. Essentially, it helps establish how many defects are considered acceptable in the inspected sample, before having to reject the entire batch. According to ISO 2859, defects can be classified into critical, major and minor, each with a specific AQL. For example, critical defects can have a very low AQL (0.1 – 0.65), because they affect the safety of the product or render it unusable. Major defects often range from 1.5 to 2.5, while minor defects can reach 4.0 to 6.5 depending on the type of product.
A structured quality control system is essential for any company operating in the sector
Quality inspection: visual analysis and functional testing
To ensure batch compliance, it is advisable to adopt a series of quality inspection procedures that start with the visual inspection and extend to specific tests, capable of highlighting aesthetic, functional or structural defects.
Visual inspection: according to ISO 2859, this is performed by taking a sample. The part is inspected in a well-lit area and is positioned perpendicular to the operator in order to avoid reflections that could alter the perception of any surface defects. If the number of defects detected in the sample exceeds the AQL limits, the batch is rejected; if it returns, it is accepted.
Functional control and dimensional checks: functional tests are tests to verify closure, dispensing capacity, resistance to internal or external pressures depending on the type of packaging (e.g. a bottle with a pump or a jar with a lid). While dimensional checks concern compliance with the measurements shown in the technical drawings (height of the bottle, diameter, thread, etc.).
Focus on the airtight closure of the bottle
Depending on the type of product, specific tests can be carried out. An example is the verification of the airtight seal of the bottle. In particular, if the container is not watertight, the product can oxidize, contaminate or leak, causing problems both in terms of use and image for the brand. Here are some tests that are good to conduct:
- vacuum leak test: the bottle, filled with air or liquid, is placed in a negative pressure chamber to verify the absence of leaks;
- screwing and tightening torque test: this test is intended both to verify that caps and caps do not unscrew too easily or, on the contrary, that the caps come off with too much or too little force, but also to ensure that capsules and lids are screwed on correctly, with the appropriate force, before performing a vacuum leak test.
During the test:- the tightening torque (i.e. the force required to screw and unscrew the cap or capsule) is measured with a torque transducer;
- the detachment force of a pressure cap or lid is measured with a stand, which allows you to detect the force required to remove the component in a controlled manner.
- dispensing and dip tube testing: for bottles equipped with pumps and dip tubes, we check the correct length and number of strokes required for dispensing to ignite, as well as the amount of product dispensed per single shot.
These tests not only ensure the airtight closure of the bottle, but also guarantee an optimal customer experience, in line with the standards that consumers expect from cosmetics, pharmaceutical or other product categories.
High resistance paint and finishes
Another key element for those who work in the packaging sector is the maintenance of the aesthetic result over time. As Eurovetrocap, we are committed to offering durable decoration solutions. To verify the robustness of the finishes, the products must be subjected to various tests, including:
- dry rubbing test: wipe or abrasive material over the surface of the bottle to assess whether the paint peels off or becomes dull;
- scotch tape test (according to ISO 2859 guidelines): a 3M type adhesive tape is applied to a portion of the decoration, removing it quickly to detect any paint detachment;
- chemical resistance tests: we use alcohol solutions or commonly used cosmetic creams, to check if the paint undergoes discoloration or abrasion when subjected to chemical and mechanical stress.
Packaging with high-strength varnish ensures that the design, logos and branding information maintain an intact appearance even in situations of heavy use, prolonged transport or exposure to changing environmental conditions.
Quality inspection and defect limits
In the conditions of sale, it is always made explicit that the total absence of defects cannot be guaranteed. The goal is to keep the defectiveness within the agreed values, in accordance with ISO 2859 and the AQL (Acceptable Quality Limit). When the customer examines the batch received to verify its acceptability or not, it is always good to follow the procedure that each supplier describes in its supply specifications, in particular the number of pieces to be analyzed and how these pieces must be selected and tested.
If the customer needs higher quality standards than those usually proposed, it is possible to make changes to the production process or intensify controls, knowing full well that this will lead to increased costs and production times.
Panoplies and supplier-customer collaboration
To make packaging quality control between supplier and customer even more transparent and shared, so-called panoplies are often adopted. These are physical samples containing examples of minor, major or critical defects. In this way, both the supplier and the customer can refer to a tangible medium and agree whether a certain defect falls into one or the other category. Panoplies greatly facilitate dialogue, reducing subjective disputes and interpretations. Through them, the two subjects precisely define:
- which aesthetic or functional characteristics are acceptable;
- which defects, although present in a small percentage, fall under the minor defects according to the agreed AQL;
- which defects are not tolerable (critical or major defects).
This approach fosters a process of continuous improvement, in which each production batch becomes an opportunity to refine quality control and implement more effective solutions.
Packaging quality control and customer satisfaction
Integrating a well-structured packaging quality control system is a strategic investment, because it affects customer satisfaction, reduces complaints and contributes to the brand’s image of reliability.
At Eurovetrocap, we have decades of experience in the supply of containers for cosmetics, pharmaceuticals and other sectors, and we know how crucial it is to maintain high quality standards through periodic inspections, laboratory tests and application of international standards. Whether it’s a bottle for luxury fragrances or a dispenser for pharmaceutical creams, the Eurovetrocap team provides all its experience to ensure compliant supplies and a high level of quality. Write to us: we accompany you from the beginning of the project to the delivery of the finished batch.
