With 2025 well and truly underway, companies are reviewing budgets and conducting strategic planning. One critical, yet often overlooked area, is the cost-saving potential of switching to non-destructive leak detection (NDLD). By investing in NDLD technology, businesses can achieve significant financial and operational benefits. Simply put, this is a must-have for food production and packaging companies focused on profitability and sustainability.
Leak detection is a vital component of quality control in the packaging process. Traditional methods such as destructive leak detection (DLD) involve opening, puncturing or immersing packages in water baths, rendering them unusable. In contrast, as the name suggests, NDLD ensures the integrity of the packaging without causing damage, delivering cost savings and operational efficiencies.
Just consider how much your current leak detection process is costing you. At a time when accurate cost calculations are non-negotiable, being aware of the financial and environmental benefits of NDLD can no longer be ignored.
The true cost of destructive leak detection
DLD comes with substantial hidden costs. Recent research conducted by Oxipack found that testing just ten packages per hour at a cost of €0.50 per package translates to €80 per day for a single production line operating two shifts. Over a 50-week production year, this adds up to €20,000 annually. When factoring in the purchase cost of a DLD machine (€6,000), the total cost for a single production line reaches €26,000. Over five years, the cumulative cost rises to a staggering €106,000.
In addition to these costs, operators must monitor the testing process closely, resulting in further inefficiencies. DLD generates waste, increases operational costs, and impacts sustainability goals, making it a less viable option in today’s cost-conscious and eco-aware environment.
Why non-destructive leak detection is the smart choice
NDLD offers an impactful alternative. Using methods like vacuum decay testing, NDLD ensures packaging integrity without damaging the product. This approach provides multiple benefits:
- Cost savings: NDLD eliminates the need to discard packaging, avoiding €20,000 in annual costs per production line. With a machine priced at €25,000 and annual maintenance costs of just €1,000, the total expense over five years amounts to €29,000—a fraction of DLD costs.
- Time efficiency: Operators simply place the package in the machine and initiate the test. The process is automated, allowing them to focus on other tasks, further reducing labour costs.
- Waste reduction: NDLD minimises packaging waste, aligning with sustainability objectives and reducing the environmental footprint.
- Enhanced accuracy: Unlike DLD, NDLD provides deterministic results, ensuring that leaks are identified with precision and reliability.
- Improved product quality: By maintaining the integrity of the packaging, NDLD helps ensure that only high-quality products reach the market, protecting brand reputation and customer trust.
Making financial sense
Switching to NDLD allows companies to recover the initial investment within the first year, with ongoing savings compounding over time. The reduced waste, lower operational costs, and improved efficiency make this an essential tool for companies aiming to optimise budgets for the coming year.
Additionally, it contributes to a safer and more sustainable workplace. By eliminating the need for operators to handle potentially hazardous materials, NDLD reduces health and safety risks. This is especially critical in industries where stringent regulatory standards are in place, as compliance becomes easier and less costly. Furthermore, reducing waste aligns with growing consumer demand for eco-friendly practices, which can enhance a company’s brand image and competitive edge.
As consumer and regulatory pressures grow, companies in the food production and packaging sectors must prioritise cost-effective and sustainable practices. NDLD offers a clear pathway to achieving both. By re-evaluating their leak detection strategies, decision-makers can unlock substantial savings while supporting environmental goals.
Furthermore, adopting NDLD demonstrates a company’s commitment to innovation. In a highly competitive market, it sets businesses apart and positions them as leaders in quality assurance. This proactive approach can also open doors to new business opportunities, including partnerships with clients who prioritise sustainability and operational excellence.
Starting 2025 with NDLD technology is a strategic move that delivers immediate and long-term financial benefits. Now is the time for business leaders to rethink their approach to leak detection, seize the cost-saving opportunities, and drive profitability in the year ahead.
With NDLD, the future of packaging is not only cost-efficient but also sustainable.