Beyond Visual Inspection: Understanding Acoustical Transparency As A Process Analytical Technology (PAT)

Advances in packaging have introduced materials and processes that are increasingly complex, making traditional visual and destructive tests insufficient for real-time quality assurance. Airborne ultrasound offers a non-destructive, contact-free method to monitor seal formation as it happens, transforming inspection from a retrospective check into a proactive process control tool. By detecting variations in density, thickness, and structural uniformity, ultrasound identifies defects as small as 500 microns and distinguishes between acceptable seals formed under different conditions. Its sensitivity to material uniformity and ability to generate real-time acoustic profiles make it ideal for environments with evolving materials and designs. Leveraging ultrasound as a process analytical technology (PAT) enables manufacturers to reduce risk, improve consistency, and ensure package integrity through science-based monitoring.

Explore how this approach redefines seal inspection and strengthens confidence in packaging performance.