A Guide to Choosing Physical Testing Equipment for Packaging

Selecting the right physical testing equipment for your packaging operation can feel overwhelming. You’re facing dozens of instrument types, multiple material categories, and a maze of international standards. RDM Test Equipment helps quality control managers and packaging engineers navigate these decisions with precision instruments designed for plastic, paper, and other flexible multi-material applications.

This guide walks you through what you need to know about physical testing equipment, from understanding core test categories to matching equipment with ASTM and ISO requirements. By the end, you’ll have a clear framework for building or expanding your testing capability.

• Physical testing equipment must align with your specific material types: paper, plastics, films, or multi-material laminates may require different instruments.
• International standards like ASTM, ISO, and TAPPI dictate which test methods you need, so identify your compliance requirements first.
• RDM Test Equipment offers over 40 years of experience in precision heat seal testing and physical testing instruments for packaging applications.
• Consider your lab workflow and throughput needs when selecting equipment: automated systems reduce operator variability and increase efficiency.
• Calibration support, training, and local service availability should factor into your equipment selection alongside technical specifications.

Physical test equipment measures the mechanical and structural properties of packaging materials. These instruments evaluate characteristics like tensile strength, seal integrity, coefficient of friction, flex resistance, and impact resistance.

Unlike chemical or barrier testing, physical property tests focus on how materials perform under real-world stresses. They help you predict how your packaging will behave during forming, filling, sealing, packing, stacking, transportation, storage, opening, re-sealing and disposal.

Quality control teams rely on physical testing to catch material defects before they reach the production line. R&D engineers use these instruments to compare suppliers, validate new materials, and optimise packaging designs.

Choosing the wrong material testing equipment creates gaps in your packaging quality control programme. You might miss critical material defects, generate inconsistent data, or fail to meet customer specifications.

The right equipment delivers accurate, repeatable measurements that you can trust. It helps you reduce waste and prevent product recalls, which serves to protect your brand reputation.

Equipment selection also affects your lab efficiency. Instruments that match your workflow, reduce testing time and minimise operator error, meaning faster results and more confidence in your quality decisions.

Heat Seal Tests, Seal Strength, and Packaging Integrity Testing

Heat seal test equipment prepares lab samples to verify that your packaging closures will protect contents throughout the supply chain. Seal strength testers measure the force required to separate sealed surfaces, while leak testing confirms airtightness and the absence of defective seals and pinholes.

For flexible packaging, you’ll need equipment that can test both peel strength and burst pressure to highlight weak points and establish safety margins. Medical and food packaging often require additional seal integrity verification to meet regulatory requirements, like ISO 11607.

RDM Test Equipment’s HSE-3 Laboratory Heat Sealer helps you determine heat seal thresholds with precise temperature, pressure, and dwell time control. This data lets you optimise sealing parameters for consistent results on the production line.

Hot Tack Testing

Hot tack testers measure seal strength immediately after the heat sealing process, before the bond has fully cooled. This is critical for high-speed packaging lines where products enter the package while seals are still warm and therefore more susceptible to bursting open or developing pinholes. Materials with poor hot tack performance can allow contents to push through fresh seals. This causes leaks, contamination, and product loss.

The HT-1XS Hot Tack Tester from RDM Test Equipment helps you select flexible materials that maintain seal integrity under production conditions for both vertical and horizontal FFS operations. You can test and compare materials before committing to full production runs.

Tensile and Elongation Testing

Tensile testing machines measure how materials respond to pulling forces. You’ll learn the ultimate tensile strength, yield point, and elongation at break for films, papers, and laminates.

RDM Test Equipment’s SST-3XS Seal Strength, Tensile, & Compression Tester helps you determine how much force a material or seal can withstand with its intelligent controller. This information helps you evaluate material quality and consistency. It’s essential for comparing different suppliers or validating incoming raw materials against specifications.

Tensile data also feeds into packaging design decisions. Knowing how materials stretch and fail helps you engineer packages that can handle real-world handling stresses.

Compression and Crush Resistance Testing

Compression testers evaluate how cartons, boxes, and other packages withstand stacking loads. This data helps you predict warehouse storage performance and transport survival rates. Crush resistance testing focuses on how materials respond to sudden impacts or localised forces. Both tests are critical for optimising material usage while maintaining protection levels.

RDM Test Equipment’s Box Compression Tester has a fully digital system to accurately test corrugated board boxes, cartons, containers, drums and other packaging materials.

Coefficient of Friction Testing

Friction testing measures a material’s slip properties, revealing how easily materials slide against each other or against equipment surfaces. Static friction determines the force needed to start movement, while kinetic friction measures the force during sliding. These measurements directly impact your packaging line performance. Materials with inconsistent friction can cause jams, misfeeds, and stacking problems during production.

The CF-400 Precision Friction Tester from RDM Test Equipment measures both static and kinetic friction in compliance with ASTM, ISO, BS, and TAPPI standards. The touchscreen interface makes operation straightforward for your lab technicians, and enables manufacturers to evaluate the impact of additives, coatings, inks, and surface treatments on material performance.

Crease or Score Bend Testing

Crease testing, often referred to as score bend testing, measures the quality and strength of score lines in corrugated board and folding carton materials. It determines the force required to bend a scored section, helping manufacturers assess whether packaging will fold cleanly without cracking, tearing, or weakening. This type of packaging test plays an important role in quality control, ensuring consistent box production, reliable converting performance, and durable finished packaging while helping to reduce production waste and rejects.

If you’d like to learn more about how score bend testing works, why it matters, and the Laboratory Carton Tester that is used to perform it, click on the image below.

Understanding ASTM Standards for Packaging Testing

ASTM International publishes test methods that define how to perform specific measurements. Many standards include data from inter-laboratory tests to verify repeatability and reproducibility of the test method. When your customers specify ASTM compliance, you need equipment capable of meeting those precise requirements.

Notable ASTM standards include:

• ASTM F88: covers seal strength testing for flexible barrier materials.
• ASTM F1921: defines hot tack testing methods.
• ASTM F2029: specifies requirements for laboratory heat sealers used in test specimen preparation.
• ASTM D1894: defines coefficient of friction testing procedures.
• ASTM F392: outlines method for Gelbo flex durability of materials.
• ASTM D1709: specifies how to determine the falling dart impact resistance of plastic films.

RDM Test Equipment designs instruments to meet these standards directly. The SST-3XS meets ASTM F88 requirements for seal strength testing, while heat seal testers comply with ASTM F2029 for specimen preparation and the CF-400 adheres to ASTM D1894 specifications.

ISO Standards and Global Market Access

ISO standards serve similar purposes but originate from different technical committees. Many international customers require ISO compliance for market access in Europe, Asia, and other regions. Your equipment must support the specific ISO methods your customers require. ISO 11607 covers packaging for terminally sterilised medical devices, which is why our range of RDM MEDeSEAL heat sealers support this standard.

Many testing instruments can satisfy both ASTM and ISO requirements with appropriate calibration and procedures. For example, the CF-800XS meets both ASTM D1894 and ISO 8295.

Other Industry-Specific Standards: TAPPI, FINAT, and DIN

Paper and pulp testing often follows TAPPI methods developed specifically for that industry. Label and narrow web converters may need FINAT test methods for adhesive applications. DIN standards from Germany remain common in European manufacturing. Your customer base and markets determine which standards you need to support.

RDM Test Equipment instruments comply with multiple standard frameworks, including ASTM, ISO, BS, TAPPI, and FINAT. This flexibility lets you serve diverse customer requirements from a single lab setup.

Testing Equipment for Fibre-Based Packaging, Paper, Carton, and Corrugated Board

Paper-based packaging requires instruments that can account for moisture sensitivity and fibre orientation. Tensile testing must follow paper-specific procedures that differ from plastics testing. Tear resistance, board stiffness, and compression testing round out the typical paper testing programme. You’ll also need equipment for measuring thickness, basis weight, and surface properties. Consider environmental controls for your paper testing lab: temperature and humidity variations significantly affect paper test results, so conditioned testing environments produce more reliable data.

Testing Equipment for Plastic Films and Flexible Packaging

Plastic films present unique challenges due to their thin gauge and tendency to stretch. Tensile testers need appropriate grips and strain measurement for film applications. Heat seal testing becomes especially important for flexible packaging. You need to control sealing temperature, pressure, and dwell time precisely to generate meaningful comparative data. Barrier testing for oxygen, water vapour, and carbon dioxide transmission complements physical testing for flexible packaging. Together, these measurements predict shelf-life performance.

Testing Equipment for Coated and Multi-Material Laminates

Laminated structures combine multiple materials with different properties. Testing must evaluate both individual layer performance and the integrity of adhesive bonds between layers. Peel testing measures laminate bond strength. Flex crack resistance testing predicts performance after repeated controlled stresses during use or transport. Multi-material testing often requires multiple instruments working together: plan your equipment acquisition to cover the full range of tests your laminate structures require.

Manual vs. Automated Testing Systems

Manual instruments give you flexibility and lower initial costs. Skilled operators can adapt procedures for unusual samples and troubleshoot problems quickly. Automated systems reduce operator variability and increase throughput. They’re ideal for high-volume testing programmes with standardised procedures.

Many labs use a combination approach: automated systems for routine production testing and manual instruments for R&D work and special investigations.

Sample Preparation Requirements

Every physical test requires properly prepared specimens, so consider how you’ll cut, condition, and handle samples before they reach your testing instruments. Inconsistent sample preparation undermines even the most accurate instruments. Invest in quality cutting tools, conditioning chambers, and handling procedures.

RDM Test Equipment offers specimen cutters – for freehand, strip, and circular samples – and preparation accessories designed to work with their testing instruments. Integrated systems reduce handling errors and improve data consistency.

Data Management and Reporting

Modern testing instruments can generate large amounts of data: consider how you’ll store, analyse, and report results when selecting equipment. Look for instruments with built-in data export capabilities. Integration with laboratory information management systems (LIMS) streamlines quality documentation.

Regulatory submissions and customer audits require traceable data. Choose equipment that supports your documentation and compliance requirements.

Technical Support and Training Availability

Testing equipment is only as impactful as the people operating it so be sure to evaluate supplier training programmes when making your selection. Initial operator training should cover equipment operation, maintenance, and troubleshooting. Ongoing support helps you get maximum value from your investment.

RDM Test Equipment includes installation, commissioning, and operator training with equipment purchases. Local support, either direct from RDM Test Equipment or from trained regional representatives worldwide, means faster response times when you need help.

Calibration and Service Programmes

All testing equipment requires regular calibration to maintain accuracy. It is crucial to understand the calibration requirements and costs before purchasing. Some suppliers, like RDM Test Equipment, offer calibration contracts that include scheduled visits and priority service. These programmes help you maintain compliance and avoid unexpected downtime.

Consider the availability of spare parts and service technicians in your region. Equipment with limited support networks can create costly delays when problems occur.

Pre-Purchase Testing and Rental Options

Reputable suppliers let you try equipment before committing to purchase, either in-person or via video calls. Aim to see how the machine interacts with your own materials and samples, as application testing confirms that instruments will work with your specific materials. Rental programmes let you add testing capability for short-term projects without capital investment, and they’re also useful for evaluating equipment before purchase.

RDM Test Equipment offers contract testing services through RDM LAB and flexible rental options. These programmes let you access testing capability while planning your equipment investments.

Prioritising Tests Based on Risk and Requirements

Start with the tests that address your biggest quality risks. Heat seal testing and/or seal integrity testing often tops the list for food and medical packaging applications. Customer specifications and regulatory requirements define mandatory tests, so build your core programme around these non-negotiable measurements. Add supplementary tests based on historical quality problems and continuous improvement goals, but focus resources where they’ll have the greatest impact on product quality.

Phased Equipment Acquisition Strategies

You don’t need to build a complete lab overnight. Many successful programmes start with essential instruments and expand over time. Prioritise equipment that serves multiple purposes: for example, a tensile tester with appropriate accessories can perform seal strength, peel, and elongation tests. Plan your acquisition timeline around budget cycles and production needs, and coordinate equipment purchases with new product launches or customer requirements.

Outsourcing vs. In-House Testing Decisions

Contract testing laboratories can supplement your in-house capabilities. They’re useful for specialised tests you perform infrequently. Compare the cost of outsourcing against equipment ownership. High-volume tests usually justify in-house equipment, while occasional tests may be more economical to outsource.

RDM Test Equipment operates contract testing services for customers who need flexible access to testing capability. This option, through RDM LAB, lets you get results while evaluating whether to invest in your own equipment.

For more information on how to build a packaging quality control test plan for multiple materials, check out our article by clicking on the image below.

Buying Based on Price Alone

The cheapest equipment rarely delivers the best value. Pay attention to the total cost of ownership, including support, calibration, maintenance, training, and potential downtime.

Build quality of instruments varies massively. Some suppliers use low-quality mechanical and electrical parts that become unreliable surprisingly quickly. A good rule of thumb is to consider the weight of the instrument for durability: for instance, RDM Test Equipment’s Hot Tack Tester weighs over 50kg, whereas cheaper alternatives weigh as little as 14kg.

Accuracy, repeatability, and reproducibility differences between instruments affect your purchasing decisions: unreliable data costs more than the equipment savings. Also evaluate equipment based on your specific application requirements. The right instrument for your needs is probably not the lowest-priced option.

Ignoring Standards Compliance Requirements

Customers and regulators expect test results from compliant equipment. Verify that instruments meet the specific standards your market requires. Generic “meets industry standards” claims need verification, so ask test equipment companies for specific standard references and compliance documentation. Non-compliant results can invalidate entire testing programmes, and the cost of re-testing with proper equipment far exceeds doing it right the first time.

Underestimating Training and Support Needs

Complex equipment requires skilled operators so budget for training time and consider ongoing competency development. New staff members need training on existing equipment – be sure to factor turnover and growth into your training requirements. Supplier support quality varies significantly; evaluate responsiveness and expertise before committing to equipment purchases.

FDA Requirements for Medical Device Packaging

Medical device packaging must demonstrate seal integrity and sterile barrier maintenance. In the US, the FDA expects validated testing procedures using appropriate equipment. IQ/OQ/PQ protocols document equipment installation and operational qualification. Your test equipment supplier should support these validation requirements.

RDM Test Equipment meets the strict quality and safety standards required in healthcare settings. The user-friendly interface supports validation documentation requirements.

Food Safety Modernization Act (FSMA) Implications

FSMA requires food manufacturers to demonstrate preventive controls in the US. Package integrity testing forms part of many hazard analysis programmes. Documented testing programmes with calibrated equipment support FSMA compliance – auditors expect to see traceable data from qualified instruments. Your equipment selection should facilitate the documentation required for food safety programmes. Built-in data logging and export features simplify compliance reporting.

Pharmaceutical Packaging Requirements

Pharmaceutical packaging faces some of the strictest testing requirements. Container closure integrity testing must meet pharmacopoeia standards. Equipment validation in pharmaceutical environments follows cGMP requirements. Your supplier should understand and support these regulatory expectations. Consider equipment designed specifically for pharmaceutical applications. Purpose-built instruments often include features that simplify validation and compliance.

Choosing physical testing equipment requires balancing technical requirements, compliance needs, and practical workflow considerations. Start by identifying your material types and the standards your customers require, and then match equipment capabilities to your specific test methods. Verify compliance with ASTM, ISO, and industry-specific standards relevant to your markets. Don’t overlook supplier support, training, and calibration services. These factors significantly impact your long-term success with any testing programme.

RDM Test Equipment brings over 40 years of experience helping packaging professionals select and implement testing solutions. Their instruments deliver the accuracy, repeatability, and standards compliance that quality control programmes demand.

What is the most important physical test for flexible packaging?

Heat seal testing is typically the most critical test for flexible packaging. Weak or inconsistent heat seals lead to leaks, contamination, and product loss. Heat seals produced too hot could develop pinholes or weak spots. RDM Test Equipment’s heat seal testers and seal strength testers help you establish optimal sealing parameters and verify production quality.

How do I know which ASTM standards apply to my packaging?

Your customer specifications usually identify required test standards. For flexible packaging, ASTM F88 (seal strength), ASTM D1894 (coefficient of friction), and ASTM F2029 (heat sealer requirements) are common starting points. Review your quality agreements and regulatory requirements to build a complete list.

Can one testing instrument perform multiple types of tests?

Many tensile testers can perform multiple tests with appropriate fixtures and software. Seal strength, peel testing, and tensile measurements often use the same base instrument with different grips and test methods. Bubble leak testers (BLTs), like the ones from RDM Test Equipment, can perform both leak and burst tests. RDM Test’s Laboratory Carton Tester may be upgraded to a 4-in-1 machine to cover crease strength, forming force, spring-back, as well as friction testing. This approach maximises your equipment investment while covering multiple testing needs.

How often should packaging testing equipment be calibrated?

Most laboratories calibrate testing equipment annually, though some applications require more frequent verification, such as every 6 months. Your quality system and customer requirements typically specify calibration intervals. RDM Test Equipment offers calibration services and support to help you maintain measurement accuracy.

What’s the difference between hot tack and heat seal strength testing?

Heat seal strength testing measures the force required to separate a fully cooled seal. Hot tack testing measures heat seal strength immediately after sealing, before the bond cools. Hot tack performance predicts how seals will behave on high-speed packaging lines where products contact freshly-made hot seals (that are their most vulnerable).

Should I buy or rent testing equipment for a new project?

Rental works well for short-term projects or equipment evaluation before purchase. RDM Test Equipment offers flexible rental programmes that let you access testing capability while assessing your long-term needs. Purchase makes more sense when you have ongoing testing requirements that justify the capital investment.

How do I reduce variability in my physical testing results?

Consistent sample preparation, conditioned samples and testing environments, and trained operators reduce variability. Automated instruments like RDM Test Equipment’s touchscreen-operated testers minimise operator influence on results. Regular calibration and maintenance ensure your equipment performs accurately over time.