Flexible Packaging Test & Specification Data Sheet

Keep the result with its test context

A bare OTR, WVTR or seal-strength number cannot be compared safely. Record the named method or agreed procedure, specimen orientation, conditioning and test conditions, result units, sample identity and test date beside the result.

Method and revision
Temperature and relative humidity
Sample, lot and orientation
Result, units and test date

Choose tests from the product failure risks

Start with the packed product, intended shelf life, distribution environment, filling and sealing process, and likely failure modes. That review decides which film and finished-pack checks are relevant; it does not justify running every listed method by default.

Oxygen, moisture, aroma and light risks
Grease, compatibility and puncture risks
Seal contamination and closure use
Handling, packing and distribution risks

Separate film properties from finished-pack evidence

Film thickness and barrier transmission results describe a specimen under stated conditions. Seal, leak, feature-position and filled-pack checks answer different questions. Keep these evidence levels separate so a material result is not presented as proof of final package performance.

Film or laminate specimen
Converted empty pouch
Sealed representative pouch
Filled pack using the intended process

Close the record with approval and change control

Put the agreed values, open questions and acceptance criteria into one revision-controlled record. When the product, dimensions, laminate, feature, artwork or process changes, issue a new revision and identify which checks must be repeated.

Buyer and supplier approval
Document identifier and revision
Accepted values and open items
Change reason and revalidation decision

Field map

What belongs in a test and specification data sheet?

The units below are recording formats, not target values. Use the unit required by the agreed method or commercial specification and keep both sides of the comparison in the same unit.

Field	Record	Unit or format	Use
Packed product	Name, physical form, reference batch and review date	Text / YYYY-MM-DD	Defines what the evidence applies to
Fill target	Nominal fill and permitted tolerance	g or kg	Connects pack size to the actual product
Flat pouch dimensions	Width × height × bottom gusset	mm	Dieline, filling and packout reference
Finished laminate thickness	Overall result and layer breakdown when known	µm	ASTM F2251 or an agreed procedure
Layer sequence	Outside-to-inside material list	Text	Identifies print, barrier and sealant direction
Oxygen transmission rate	Result, temperature, RH and oxygen conditions	cc/(m²·day)	ASTM D3985-24 or an agreed method
Water vapor transmission rate	Result, temperature and RH	g/(m²·day)	ASTM F1249-25 or an agreed method
Seal strength	Peak or average force, specimen width and failure mode	N/15 mm or agreed unit	ASTM F88/F88M-23 or an agreed method
Heat-seal window	Temperature, dwell time and pressure settings reviewed	°C, s, kPa	Line qualification with the intended equipment
Seal geometry	Top, side and bottom seal widths	mm	Dieline and filled-pack review
Zipper position	Top edge to agreed zipper reference	mm	Opening, filling and top-seal clearance
Tear-notch position	Edge to notch reference on each side	mm	Opening access and artwork clearance
Other feature position	Valve, window or hang-hole coordinates and size	mm	Function, registration and artwork review
Gross leak test	Method, vacuum or pressure, time and sample preparation	kPa and s	ASTM D3078 within its scope or an agreed method
Filled-pack checks	Named check, conditions and observable outcome	Method-specific	Confirms the intended product and process
Sample plan	Quantity, lot selection and test date	n / lot / YYYY-MM-DD	Makes the result traceable
Acceptance criteria	Pass/fail limits in the same units as the result	Method-specific	Agreed before approval
Approval record	Document ID, revision, approvers and decision date	Text / YYYY-MM-DD	Controls release and later changes

Method references

Verify the controlled method before testing.

D3078 is a gross-leak method and notes that small leaks may not be detected. Method editions and suitability can change; confirm the controlled standard and agreed conditions before testing.