Package Leak Testing That Shows You the Exact Problem
Manufacturers across food, pharma, and medical packaging face the same challenge: how do you ensure a sealed package will hold up through shipping, storage, and use?
Vacuum decay and other non-destructive tests can confirm whether a leak exists. But when the stakes are product safety, recalls, and brand reputation, you need more than a pass/fail answer — you need to know where the leak is happening.
That’s why Bubble Emission testing (ASTM D3078) has become the go-to method for companies who want both speed and clarity. In 30 seconds or less, it not only detects the leak but makes it visible, so QA teams can solve the root cause before product ever leaves the plant.
Introduction to Bubble Emission Testing
Bubble emission testing is a straightforward, ASTM-recognized method for identifying leaks in flexible and rigid packages. The process is simple: the package is submerged in a water-filled chamber, a vacuum is applied, and if there’s a leak, escaping gas creates visible bubbles.
The importance is clear:
- Ensures sterility and safety
- Extends shelf life by catching micro-leaks
- Prevents contamination
- Provides visual proof for audits and compliance
Unlike vacuum decay, which only shows a pressure change, bubble emission tells you exactly where to look.
Where Bubble Emission Fits in the Leak Detection Landscape
Leak detection methods include:
- Bubble emission testing (ASTM D3078) – See where leaks occur in real time
- Vacuum decay testing – Detects pressure changes without showing location
- Pressure decay testing – Primarily for rigid containers
- Helium leak detection – Extremely sensitive, but complex and costly
- Dye penetration – Destructive, slower, and less practical for daily QA
Each has a role, but when speed, clarity, and root-cause analysis matter, bubble emission stands out.
Advantages of Bubble Emission in Quality Assurance
Bubble emission offers several key benefits:
- Immediate visibility: Pinpoint leaks in under 30 seconds
- Actionable results: Visual proof allows faster root-cause analysis
- Versatility: Works with flexible pouches, rigid containers, stick packs, and more
- Cost-effective: No wasted product from destructive testing
- Audit-ready: ASTM D3078 compliance builds trust in QA systems
Vacuum decay may quantify leak rates, but bubble emission is what helps QA teams fix the underlying issue.
Fundamentals of Bubble Emission Testing
Principle of Operation:
- Submerge package in a sealed water chamber
- Apply vacuum, pulling air out of the package
- Watch for bubbles forming at defect sites
Key Components of the System:
- Test Chamber: Designed to hold various package formats securely
- Vacuum Source: Creates the required pressure differential
- Visual Window: Provides clear visibility for bubble formation
Success is simple to see: no bubbles means no leaks.
Packaging Types Suited for Bubble Emission
- Flexible Packaging: Pouches, bags, sachets — ideal for catching pinholes or seal defects
- Rigid Containers: With proper setup, bubble emission works on vials, bottles, and cans
- Vacuum-Sealed Packaging: With FlexPak’s VAC Attachment, even vacuum packs can be inflated and tested effectively
This versatility allows one testing method to support multiple product lines across food, medical, and consumer goods.
Step-by-Step: Running a Bubble Emission Test
Step 1: Preparation and Setup
Place the package in the chamber, fill with water, and connect to vacuum source.
Step 2: Apply Vacuum
Draw chamber pressure down to your desired pressure. If you need help determining what pressure to test at – just give us a call!
Step 3: Monitor for Bubbles
Leaks are visible within seconds. The exact location is revealed for immediate troubleshooting.
Success looks like no bubbles. If bubbles form, you know exactly what to fix.
Bubble Emission vs. Vacuum Decay: The Key Differences
| Feature | Bubble Emission (ASTM D3078) | Vacuum Decay |
| Leak Location | Visible at defect site | Not shown |
| Speed | <30 seconds | 30–90 seconds |
| Root Cause Analysis | Direct, visual, actionable | Requires secondary testing |
| Packaging Types | Flexible, rigid (with fixtures), sachets, stick packs | Good for Pharma/Medical or rigid packaging |
| Cost Efficiency | Low setup cost, quick ROI | Higher sensor calibration/maintenance |
| Clarity for QA Teams | Immediate visual proof | Data requires interpretation |
Both are ASTM-approved, but only bubble emission shows you where the problem is.
Real-World Applications Across Industries
- Meat & Seafood: Catch seal failures that lead to contamination and recalls.
- Dairy & Beverages: Ensure pouches and bottles hold up through shipping.
- Snacks & Packaged Goods: Prevent micro-leaks that cause staleness.
- Pet Food: Stop odor leaks before they erode brand trust.
- Medical & Pharma: Visual proof supports ISO 11607 and USP <1207> compliance.
Trusted by brands like Kroger, Nestlé, Hershey’s, and Costco, bubble emission testing delivers clarity and speed across industries.
Compliance and Standards
Bubble emission aligns with ASTM D3078, making it a globally trusted method for package integrity testing. While vacuum decay aligns with USP <1207> and FDA-recognized CCI guidance, bubble emission often serves as the first-line test because of its speed and clarity.
It’s the most practical, audit-friendly option for plants that need daily QA without slowing production.
Challenges and How to Overcome Them
- Large Packages: Require larger chambers, but can still be tested effectively
- Opaque Packaging: Fixtures and positioning ensure visibility at likely leak sites
- High Throughput Lines: Larger units allow for testing multiple packages at once
FlexPak systems address these challenges with custom chambers, VAC Attachments, and purpose-built fixtures.
Future of Leak Detection: Bubble Emission + Data
The next generation of bubble emission testing integrates digital logging, automated chambers, and data analytics. This means:
- Automated defect recording
- Trend analysis for sealing equipment
- Predictive maintenance to reduce downtime
Pairing simple visual proof with smart data makes bubble emission even more powerful for QA teams.
Economic Benefits of Bubble Emission
- Lower Recall Risk: By solving root causes before distribution
- Less Waste: Non-destructive testing saves product and materials
- Faster QA: Tests take seconds, not minutes
- Audit Confidence: ASTM standard + visible results = easy compliance
Every dollar saved in recalls and rework comes from knowing where the problem is — something only bubble emission shows.
Conclusion: See the Leak, Solve the Root Issue
Vacuum decay and other methods may confirm whether a package leaks, but only bubble emission shows you exactly where. That visibility is what allows teams to take corrective action, prevent recalls, and protect brand reputation.
With FlexPak’s ASTM D3078 bubble emission systems, you get results in 30 seconds or less, with visual proof your team can act on. It’s not just about detecting leaks — it’s about solving them.
👉 Ready to see where your leaks really are?