Consumables: costs & challenges

Currently, all four main methods to leak test flexible packaging require that you use a septum, which you have to manually adhere to the packaging, and then manually perforate the septum with a hollow needle to perform the leak test.

This is the main reason why leak detection has not been automated as of today.

A/ Leak, gas septum & needle – the costs:

A septum takes the form of a sticker that is adhered to the flexible packaging to be tested. The septum’s main function is to provide a leak-free seal to maintain the gas pressure inside the system. In other words, it helps to avoid creating an additional leak when the packaging is perforated with a needle.

– One test = one septum. A septum cannot be reused.

– A leak septum can be used to perform either a leak or a gas test.

– A gas septum can be used only to perform a gas test.

Leak septum are much more expensive than gas septum.

Septum Perforated by Hollow Needle

Septum perforated by a hollow needle.

Some users are spending 25,000 to 35,000 USD per year on leak septum’s alone.

With the AlphaTower and the GammaTower, all these costs will disappear entirely, as both have an integrated thin conical stainless-steel pointer that does not need any Septum to perform tests.

Leak septum Detection
Leak septum

Cost: 200 USD / 1,000 pcs.

Stainless-Steel Needle Testing
Stainless-steel needle

Needs to be changed regularly.

B/ Additional challenges:

When there is little space between the product and the packing (headspace), the hollow needle could pierce the food and partially block the needle. As a consequence, the flow would become restricted, or even cease, which results in the gas test or leak test becoming compromised. This is entirely avoided with the Astaara range of products, due to the use of a thin conical stainless-steel pointer, therefore avoiding any partial or total blockages.

C/ Plastic film usage:

Plastic Roll Alamy

Plastic film being sold by the weight, it is understandable that little is done to convince Manufacturers that the thickest film is not necessarily the best way to optimize the sealing of a product.


The quality of the sealing depends upon a number of factors, selecting the thickest film possible is not one of them. By specifically trying and testing the sealability of thinner films, a Manufacturer can actually achieve better sealing results, reduce plastic consumption and hence generate costs savings.

D/ Conclusion:

With the Astaara range of products, all consumable costs will completely disappear.

Also, by testing the sealability of thinner films, you can reduce your cost substantially, as films are sold by the weight.

In addition, if you are testing products like chocolate bars, cookies, mooncakes…..the results of the test will not be compromised by a blocked needle.