https://ascendpkg.com/wp-content/uploads/2025/07/Lower-manifold-system.jpg 1250 2000 AbstraktMarketing /wp-content/uploads/2021/09/Ascend-Logo-Blue_0001_Blue-Ascend-Logo-300x108.png AbstraktMarketing2025-07-25 19:37:392025-07-25 21:09:51A Guide to Lower Manifolds for Bottle Filling Equipment What Is the Blue Dye Test?
Blue dye testing is a type of package leak detector that’s considered traditional, but it has its drawbacks. It’s destructive, making the blister pack unusable after testing, and raises environmental concerns due to the disposal of the dye-filled water.
The Cons of Using the Blue Dye Test
With more and more companies striving to reduce their environmental impact, it’s time to explore non-destructive leak test methods. By switching to non-destructive methods, you can eliminate the need for blue dye and maintain the integrity of the blister packs.
If you’re still not sure if you should make the switch to non-destructive leak testing methods, let’s review some drawbacks of using the traditional blue dye testing method.
Misinterpreted Packaging
One of the main concerns is that blue dye tests can be easily manipulated or misinterpreted. Sometimes, even a minor defect or hairline crack can go unnoticed, potentially compromising the contents inside. Furthermore, tests often require blowing air into the packaging, which may not accurately reflect real-life conditions. This means that a package could pass a blue dye test but still fail under normal handling or transportation.
Product Waste
Unlike the old ways, non-destructive methods don’t require the tested blister packs to be disposed of, whether they pass or fail the test. This means that manufacturers can reuse the packs that pass the test, or even recover the valuable drugs inside the packaging to be repacked. Using non-destructive leak test methods saves money by reducing the need for new blister packs and gives you an eco-friendly solution that helps minimize waste production.
Incineration Cost
Destructive testing methods for pharmaceutical packaging generate product waste and contribute to high energy consumption and CO2 emissions. By using non-destructive methods, faulty packs can be recovered and the tablets and capsules inside can be repackaged, reducing the need for incineration and saving on disposal costs. Not only does this help minimize waste, but it also reduces energy consumption and environmental pollutants.
Untreated Water Waste
Untreated wastewater can’t simply be flushed down the drain. Non-destructive leak testing methods save precious water resources and reduce the risk of contamination while slashing associated treatment and disposal costs. By embracing non-destructive testing, you can protect the environment and boost your profits simultaneously.
Subjective Test Results
Advanced test methods provide non-destructive solutions that align with USP 1207 guidelines. With these new technologies, multiple blister packs can be tested at once, and a simple ‘pass/fail’ can be given for each individual blister pocket. Non-destructive methods offer incredible accuracy by identifying micron holes as small as 5µm! Blue dye testing simply can’t match this level of precision.
Benefits of NDT Methods
Switching to NDT methods has a variety of benefits:
- Cost Savings: With NDT, your packaging survives the testing process unharmed, allowing your product to make it to market while saving you money and resources.
- Efficiency: With NDT, you can evaluate your assets thoroughly and quickly, a crucial factor for ensuring continued safety and performance at your facility.
- Accuracy: NDT is proven to be more accurate, predictable, and reliable than destructive testing methods.
Non-Destructive Leak Testing Equipment: Sepha Multi-Q
At Ascend Packaging Systems, we offer a few types of non-destructive leak testing equipment.
The Sepha Multi-Q is a non-destructive, deterministic, and multi-functional CCI testing system designed to detect leaks in non-porous, rigid, or flexible packaging. This modern NDT machine is compatible with a variety of testing methods, including vacuum decay (ASTM F 2338-09) and pressure decay (ASTM E290-13).
Sepha’s lab-scale Multi-Q system is designed with a small footprint and offers the flexibility to switch between testing methods, depending on product and specified test requirements. Its CCI testing methods are easily changed, and relevant recipes for selected attachments are available. The Multi-Q’s non-destructive and deterministic test methods provide quick, reliable, and repeatable results, improving leak detection accuracy and reducing costs.
Other features of the Sepha Multi-Q include:
- Quick test time and recipe-driven
- Fast, tool-less changeover
- Batch data stored or printed
- Built for cGMP environments
- Grade 304 stainless steel body
The Sepha VisionScan 3D
The Sepha VisionScan 3D is a blister leak test solution that takes NDT methods to the next level. This next-generation machine is built around a new, patented 3D scanning technology that uses vacuum deflection to test the integrity of pharmaceutical blister packs.
With the latest technology, the VisionScan 3D provides a clear pass or fail result for each blister package down to the exact cavity where leaks exist. The tested pack is unharmed, allowing your quality tablets to be put back on the production line. This simple but vital, non-destructive element saves you money and time and provides you with a more modern, reliable leak detection process.
Other features of the Sepha VisionScan 3D include:
- Flexible, mobile tabletop device
- Tool-less that are ideal for production lines running multiple products
- Can test multiple packs per cycle
- Simple operator use via a touch screen interface
- Patented, 3D volumetric scanner combined with differential vacuum and pressure
- Rapid test time down to 60 seconds for micron holes and 30 seconds for gross holes
- Capable of storing and exporting data for audit and quality control purposes
To learn more about Sepha’s leak detection equipment, reach out to Ascend today. Our experienced team can help you select the right type of non-destructive leak testing equipment for your pharmaceutical packaging needs.
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