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Packaging quality issues rarely occur without warning. Suddenly a sealing seam opens unexpectedly, the bond comes apart, barrier properties deteriorate or processing problems accumulate in production. The visible symptoms are often clear – but the actual causes are not.

This is exactly where the damage analysis begins. And in many cases the first route leads to material analysis.

Why the actual cause often remains hidden

When an error occurs, the focus is often initially on the production process. Have machine parameters been changed? Were there any fluctuations in processing? Are the conditions in the warehouse responsible?

These questions are important. Nevertheless, practice shows again and again that the actual cause often lies in the material itself.

Even small changes in the raw material, layer structure or material properties can have a significant impact on the functionality of packaging. The problem: Such changes are usually not visible to the naked eye.

A systematic material analysis helps to replace assumptions with facts.

Typical damage patterns with flexible packaging

Many quality problems can be traced back to some recurring damage patterns.

Let the damage speak for itself through appropriate analysis and thereby understand errors in depth before measures are implemented.
Karsten Schröder

Delamination of composite materials

If individual layers separate from one another, adhesion promoters, adhesives or process parameters may be the cause. Material changes on the supplier side are also conceivable.

Abnormalities when sealing

Insufficient seam strength or unstable sealing parameters can indicate changes in the sealing layer, contamination or unsuitable material combinations.

Change in barrier properties

If oxygen or water vapor permeability increases unexpectedly, it is worth taking a closer look at the layer structure and the barrier materials used.

Processing problems

Wrinkling, web instability or unexpected friction properties can be caused by material fluctuations or different raw material qualities.

In all of these cases the same question arises: Does the material actually meet the expected properties?

Material analysis as a tool for root cause research

Modern analyzes enable significantly deeper insight than classic incoming goods inspections.

Material identification using FTIR

With the help of infrared spectroscopy (FTIR), plastics and other materials can be identified and compared with each other.

This makes it possible to check whether the materials used actually correspond to the intended materials or whether there are deviations.

Examination of the layer structure

Especially with composite films, the exact composition determines the subsequent function of the packaging.

Microtome sections and microscopic examinations make individual layers visible and allow statements to be made about material combinations, layer thicknesses and structural structure.

Thermal analyses

Methods such as DSC analysis (Differential Scanning Calorimetry) provide information about melting behavior, crystallinity and material composition.

This allows differences between the target and actual states to be recognized, which have a direct impact on processing and function.

Why guesses often become expensive

Time pressure often arises when processing complaints. Production stoppages, delivery bottlenecks or quality deviations require quick decisions.

However, this is exactly where there is a risk: If causes are only assumed, there is a risk that measures will be targeted at the wrong adjustment screws.

Machine parameters are adjusted, processes are changed or suppliers are changed without the actual cause being clearly identified.

A well-founded material analysis, on the other hand, creates a reliable basis for decision-making and often shortens the path to actually solving the problem.

Material analysis is more than just processing complaints

Damage analysis is often only commissioned when a problem has already arisen. Material analysis can also be used preventatively.

Typical fields of application are:

• Reviewing new supplier materials
• Comparison of alternative qualities
• Securing material changes
• Evaluation of recycled content
• Quality monitoring in goods receipt
• Documentation for critical applications

If you understand material properties early on, you can avoid many later problems.

Conclusion

Packaging provides clues as to its errors – you just have to be able to read them correctly. While visible damage often only represents symptoms, the actual causes often lie in the material structure or in changed material properties.

Material analysis provides the necessary facts to evaluate quality problems in a well-founded manner and to systematically narrow down the causes. It is therefore a central tool for damage analysis and supports companies in making well-founded decisions instead of reacting to assumptions.

Our tip

If quality deviations occur or material changes are suspected, it is worth taking an analytical look at the packaging itself. Modern testing methods can provide valuable information and help to identify causes more quickly and reliably.

Related articles

The discussion around PFAS in packaging has gained significant momentum in recent months. At the latest with the PPWR limit values, many companies are facing the same question:
How can PFAS in flexible packaging be reliably detected – and which analytical approach is sensible?

As part of an Inno-Talk, Dr. Tim Schlüter (Innoform Testservice) presented the current state of analytics. The key finding:
“There is currently no harmonized analytical method – but there are practical ways to reliably assess PFAS.”

This is precisely where the expanded testing services at Innoform Testservice come in.

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PFAS Analytics: Challenge and Reality

PFAS comprise a very large substance group with several thousand potential compounds. A complete individual substance analysis is therefore hardly feasible in practice.

At the same time, the PPWR demands clear limit values for food contact packaging. This creates a field of tension:

• very low limit values
• complex substance groups
• lack of standardized test methods

Analytics must therefore proceed pragmatically and work with suitable screening strategies.

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Additional Challenge with Polyolefins

This is particularly relevant for polyolefins such as PE and PP, which make up a large proportion of flexible packaging systems.

In practice, PFAS are often deliberately used here:

• already in the raw material as an additive
• during film extrusion as a processing aid

The goal of these so-called processing aids is to:

• improve melt properties
• stabilize material flow in the extruder
• optimize the surface quality of the film

These functional additives can lead to measurable fluorine contents even in supposedly non-critical materials.

For assessment, this means:
PFAS entries are often system-inherent and not always fully documented. Analytical verification is therefore necessary.

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Total Fluorine as Key to Quick Guidance

A central approach is the determination of total fluorine content (Total Fluorine, TF).

This enables:

• a quick assessment of potential PFAS contents
• prioritization of materials
• targeted selection of further tests

The method is based on combustion of the sample followed by determination of fluorine content.

Advantage

• Detection of all fluorine-containing components
• independent of known individual substances
• suitable as a screening method

Limitation

• no direct statement about individual PFAS
• further analytical steps required

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Differentiation: Where is the Relevant Fluorine?

For more precise assessment, total fluorine content is further differentiated into:

• inorganic fluorine (TIF)
• organic fluorine (TOF)

The organic fluorine fraction is particularly relevant, as this is where possible PFAS are contained. This is derived from the difference between total fluorine and inorganic fluorine.

The procedure requires:

• reproducible measurement conditions
• coordinated temperature control
• experience in interpretation

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Limitations of Current Methodology

The methods discussed in the regulatory environment are not suitable without restrictions.

In particular, limitations become apparent with:

• incomplete implementations of individual procedures
• methodological differences between guidelines and practical implementation

Analytics therefore primarily delivers one thing:
reliable guidance, but not yet complete standardization.

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Practical Question from the Inno-Talk

A frequently asked question from the Inno-Talk was:

Must testing be performed if no PFAS are intentionally used?

The answer is clear:

• What matters is the PFAS content in the material
• the origin of the substance is of secondary regulatory importance

Even unintentional entries from raw materials, additives or processes must be taken into account.

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Innoform Testservice: Extended Capacity for PFAS Analyses

To meet the increasing requirements, Innoform Testservice has expanded its capacity.

We can currently:

• perform total fluorine determinations routinely
• offer differentiations between inorganic and organic fluorine
• systematically assess materials for PFAS risks
• process larger sample volumes at short notice

This enables us to provide the necessary analytical capacity to give companies well-founded guidance on the PFAS content of their packaging.

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Inno-Talk Available as Recording

The content of this article is based on the Inno-Talk on PFAS analytics with Dr. Tim Schlüter.

The recording is still available and offers:

• detailed insights into the test methods
• practical examples
• answers to typical questions from the industry

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Conclusion

The regulatory requirements are defined, the analytical standards are still developing.

For companies, this means:

• proceed systematically
• understand risks
• use analytics in a targeted manner

Total fluorine determination offers a practical entry point for this.

With its expanded capacity, Innoform Testservice supports
reliably assessing PFAS in flexible packaging and making well-founded decisions.

What is it about?

EU Regulation 2022/1616 sets out how plastics may be recycled if they are to come into contact with food again at a later stage.
It is intended to ensure that recycled materials do not contain any substances harmful to health.

For the flexible packaging industry (films, bags, laminates), this regulation has very specific implications.

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First things first1. First things first

Not all recycled materials are suitable for use in food packaging.
The key factor is not whether a material is “recycled”, but rather:

• how it was recycled
• which method was used
• where the waste material comes from

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What is currently allowed – and what isn’t?

✅ Permitted (as of April 2026)

1. Mechanical PET recycling

• Applies only to PET
• The recycling process must:
  • assessed by the EFSA
  • and be registered throughout the EU
• Works particularly well for:
  • bottles
  • plain PET film (single-material)

This means it can generally be used for PET-based flexible packaging, provided it is sorted by type.

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2. Recycling in closed and controlled cycles

• The material comes from defined, monitored systems
• Examples:
  • production leftovers
  • Return schemes
  • B2B cycles
• Advantage:
  • hardly any foreign substances
  • low risk of contamination

These sources are particularly interesting for film manufacturers, but they are organisationally challenging.

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❌ Not permitted (for food contact)

• Mechanically recycled PE or PP films from household waste
• Multilayer recycled materials from open collection systems
• Recycled materials without proven decontamination performance

These materials must not be used for food packaging.

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Why does this affect flexible packaging in particular?3. Why does this affect flexible packaging in particular?

Flexible packaging has three structural drawbacks:

1. Many material combinations
   Composites are difficult to assess definitively
2. Large surface area
   greater exposure to potential contaminants
3. Unregulated material flows
   Origin and previous use often unknown

The Regulation assumes that:

If you don’t know exactly what was in the plastic before and how it’s made, you shouldn’t simply reuse it for food.

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Chemical recycling – a ray of hope, but not yet a solution4. Chemical recycling – a ray of hope, but not yet a solution

Chemical recycling is mentioned in the Regulation, but:

• not yet approved for general use
• permitted only as “new technology” under observation

Chemical recycling is particularly strategically important for flexible packaging, but there is as yet no general regulatory approval.

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What does this mean in practical terms for the industry?5. What does this mean in practical terms for the industry?

• ✅ PET continues to grow in importance
• ✅ Design for recycling is a requirement, not an option
• ❌ PE/PP PCR testing for food remains severely restricted❌ PE/PP‑PCR für Food bleibt stark eingeschränkt

In future, companies must be able to answer

• Where does the recycled material come from?
• Which method was used?
• Has the process been approved and registered?

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Strategic implications for manufacturers of flexible packaging

The regulation clearly steers the industry in the direction of:

• fewer materials
• simpler structures
• controlled cycles
• Early coordination between design, recycling and regulation

Recyclability is becoming a regulatory requirement, not just a sustainability claim.

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Fazit

EU Regulation 2022/1616 is not a ban on recycling, but a clear market selection:

Only recycled materials from processes that have been verified as safe may be used in flexible food packaging.