A Thirst for Perfection

Beverage packaging encompasses many different factors. But whether you’re a can maker or can filler dealing with soda, energy drinks, or canned cocktails, one thing remains the same – there is an undeniable thirst for perfection.

Every single aspect – from the taste, to the branding, to the packaging - has to follow a formula. Every single can of soda, water, beer, coffee, pre-made cocktail, or energy drink, has to be perfect.

For those working in the beverage industry, there’s a big responsibility. These professionals are responsible for crafting more than just a beverage, they are creating a brand. A brand that will need to be safe, sustainable, customer-centric, durable, cost-effective, and reliable. And this brand can only become a success if the highest quality of packaging is produced.

The manufacture of packaging is perhaps the most crucial component to the beverage production process. It’s the first thing a

consumer will notice - you can’t have a torn label, scratched can, or a leaking seam.

If you’re building a brand, it just takes one mistake to destroy all efforts.
We understand this. We appreciate the importance of quality control more than anyone. And it’s why we’re here. To act as your partner in perfection.

Providing crush testing tools to ensure cans can withstand the pressure, glossmeter checking to ensure the quality of your inks and coatings, and seam inspection instruments to prevent cans from leaking – we offer a varied range of solutions to test across a wide range of applications.

At Industrial Physics, we ensure that you have the tools you need to protect the integrity of your packaging, materials, and finished product – making sure that all the hard work you’ve poured into that brilliant batch can be enjoyed to the maximum. 

Get in touch to speak with the team at Industrial Physics

Across our family of brands, including CMC-KUHNKE, TQC Sheen, Quality By Vision, Systech Illinois, and Eagle Vision, we’ve been supporting beverage manufacturers and production lines across the globe for almost a century.

As experts in test and inspection solutions, we provide an extensive portfolio of instruments specifically created to ensure the quality of packaging across the beverage industry.

Our products test for a variety of applications across the entire production line. Put simply, it’s our job to quench that undeniable thirst for perfection.​

Quenching the thirst of your customer is about more than delivering something delicious. You need to produce a package that will pop off the shelves.

That’s where we come in - providing can makers and can fillers with the test and inspection solutions needed to perfect your packaging on production lines.

From leak detection, to labelling inspection, to code reading, our solutions are diverse and extensive – but across our product portfolio, you can rest assured that the quality of your packaging will be safeguarded.

It takes a whole team of experts to bring a beverage brand to life. Manufacturers, production managers, brand directors – everyone has a role to play. And there’s a lot going on.

Producing, tasting, storing, canning, sealing, packing, designing, and not forgetting testing.

You produce it. You taste it. You smell it. You taste it (again). You fill it. You seal it. You label it. You package it.

Our products test it. Bish it. Bash it. Bosh it. Probe it. Rub it. Grind it. Test it (again).​

What are the biggest trends within beverage packaging product right now?

We understand that demands on manufacturers and production lines change every day. But how does this impact your quality control processes? And your test and inspection needs?

What stresses, challenges, and obstacles are manufacturers facing in a quest to create a spectacular soda or the perfect canned iced coffee?

We spoke to our internal product specialists and reached out to some of our friends – experts in beverage manufacturing and quality control – to uncover the biggest trends within beverage packaging production today.

And we explored just how these issues are impacting quality control...

At Industrial Physics, we provide solutions across the entire beverage production line.

Check out how each of our products provide all the ingredients you need for perfection on your production line - every step of the way!

Get in touch for more information!

How is sustainability impacting quality control?

A drive towards sustainability is rapidly disrupting supply chains across many industries. So, it’s hardly surprising that this topic touches many aspects of packaging, production, and quality control processes in the beverage space.
There’s an expectation on manufacturers and production lines to do everything they can to discover sustainable solutions.

Across all industries, manufacturers have been tasked with standard requests to reduce energy usage, water consumption, and material usage. And the same is true for the beverage industry.

As important as these initiatives are, cutting down waste on production is only one piece of the puzzle - there’s a growing demand to use more sustainable packaging when bringing products to market.

Consumers are thirsty for their favorite drink, but they could just as easily get a taste for a new, more sustainable brand...

In 2020, a leading bottled water company revealed a new bottle that was made using 100% recycled plastic.

New sustainable materials disrupting production lines

All over the world, and across multiple markets, beverage brands are adapting their packaging processes to become greener – in fact, just this year a large brewer announced they were making new packaging using barley.

And in 2020, a leading bottled water company revealed a new bottle that was made using 100% recycled plastic and designed using an engraved logo – removing the need for additional labelling.

As the demand for sustainable packaging increases, investment in innovation to support the initiative is only going to grow. According to John Maddox, President of SBA-CCI,. Jackson Fla., ‘Hundreds of millions of dollars are being invested in recycling and sustainability. New technologies, which were heretofore considered impractical or too costly, are now being reconsidered and in many cases being prepared for implementation in order to meet 2025 goals.'

But as beverage brands scour to source new sustainable materials that provide eco-friendly packaging alternatives, the impact this will have on quality control has to be considered.

Will new testing methods need to be introduced? How will this impact testing standards? And what impact will this have on testing instruments already in place that need to be updated?

These are all questions that packaging manufacturers, business leaders, and testing partners alike must keep front of mind as the beverage market continues to innovate while striving for a new, more sustainable world.

The impact on packaging initiatives

As we become more environmentally conscious, businesses are exploring new ways to package up their beverage – both through the adoption of different materials and the use of these materials to create new shapes and styles.

This move towards sustainable packaging gives brands an opportunity. There’s a real chance for manufacturers to seize this moment, adapt, and get creative with packaging.

But if manufacturers are using new materials in their packaging, it’s critical that the right test and inspection equipment is in place to ensure quality. This means that businesses need the best test and inspection solutions available. However, it also highlights the need for the test and inspection space to continuously innovate.

If beverage manufacturers are introducing a wider breadth of materials into their production line, then it’s critical that testing partners like Industrial Physics are responding to this – either through the advancement of existing equipment or the invention of new instruments to accommodate new materials.

It's more important than ever to have a test and inspection partner who understands the specialism and can adjust to the ever-changing needs of the industry.

42% of U.S. and UK consumers seek out products that are recyclable or that use sustainable materials when making day-to-day purchases.

74% of consumers would pay more for sustainable packaging.

In 2022, we surveyed 255 packaging decision makers across the globe - finding out exactly how they believed sustainability initiatives were impacting quality control. 

Access our FREE report, '2022 Global Outlook of Sustainable Packaging' now!

Industrial Physics instruments - offering sustainable solutions

With no product waste and no packaging waste, the Auto XTS is a true zero waste solution. There truly is no good reason to keep destroying tens of thousands of perfectly good and sellable cans per year if a responsible and sustainable alternative exists.  And it does. The Auto XTS has the power to offer canning manufacturers a truly sustainable solution.

The benefit of an Auto XTS is that the system allows the plant to continuously test while reducing the time from a problem occurring to discovery in just a few minutes, as opposed to hours - saving even more CO2. The following case study is based on a very small sample from a plant (examining 16 cans per line every 4 hours).

A quick calculation of the environmental impact of destructive testing – both labor and can waste vs the AUTO-XTS demonstrates an advantage of 24-30 tons of carbon emissions per year in favor of AUTO-XTS.

CO2 FOOTPRINT – DESTRUCTIVE SEAM TESTS 
 

• 3 seam checkers (one per shift) performed by operator: 3.2T CO2 for commute + 2.6T office space = 17.4T  

• Total equipment footprint: 0.5T CO2 

• Can and product footprint: 170g/can ≈ 6.8T (40K cans/year) based on a 330ml can of soda (CO2 footprint of a can of soda ≈170g, can of beer ≈300-500g, bottle ≈360g) 

Total CO2 footprint for destructive seam inspection: ≈24.7T per year 

CO2 FOOTPRINT – AUTO-XTS 
 

• Equipment footprint: 0.5T CO2 per year 

• Total CO2 footprint for AUTO-XTS: 0.5T per year

 
Reduction of 24-30T CO2 per year compared to destructive seam tests 

Find out more about the CMC-KUHNKE Auto XTS!

Industrial Physics & Aquapak - working together towards a more sustainable world

Delivering sustainable solutions for our customer's is hugely important to us.

And we're passionate about using our expertise to to deliver innovative solutions that can make a difference - helping manufacturers to strive for sustainability while also ensuring the integrity of their brand and product is never compromised.

"Allowing the WVTR test to reach equilibrium means that we are confident in the results. Over the last few months, we have carried out full analysis of multi-layer samples to gain an understanding of how our customers can replicate their own WVTR testing regime on Hydropol.

Being able to build a relationship with Industrial Physics and leverage their expertise in packaging barriers was critical to the success of this programme."

Max Phippard, Quality Control Manager, Aquapak

Check out the IP & Aquapak story here!

What are the biggest game changers in the world of beverage packaging?

Brands have always had to think outside of the box when it comes to grabbing the attention of consumers. But now, we’re seeing an increasing amount of beverage companies getting creative with packaging in an attempt to draw in customers.

There’s a multitude of reasons brands are mixing things up. But whether it’s all to grab customer attention, or an effort to become more sustainable, the impact on quality control is clear – when new methods are introduced, the room for error becomes greater. So, it’s especially important to be prepared.

Powerful packaging drives sales. Whether this involves introducing bold new artwork or trying out a new type of material, there’s a huge reward for beverage brands who are able to get creative.

People love to share images of themselves enjoying their favorite drink. And as the volume of posts increases, so does the demand for trendy packaging – a clear incentive for beverage producers in the quest to keep packaging fresh.

This fascination with aesthetics means that brands have to put in the extra effort to ensure their product pops from the shelves – and one way to be successful here is to come up with new designs and formats within packaging.

The impact of aesthetics

Across the beverage market, we’re seeing more and more brands experimenting with designs. For some brands, the involves introducing open topped, shaped embossed cans – interesting manipulations of the packaging that are shaped in a unique way to grab the attention of consumers.

For others, there’s a focus on the development of highly original label and printing graphics to stand out, such as the implementation of HD beverage can printing. We’re also seeing manufacturers experiment with Tactile OV – a special coating technology that allows different surfaces to be felt when holding a can.

Manipulation of the inks and coatings on a can will also allow manufacturers to create a truly unique customer experience. For example, thermochromic inks can be used to cover a part of the can with a temperate-sensitive pigment. This advanced technology adds an extra layer to the drinker’s experience – it could, for example, change color when the beverage reaches a different temperature.

Photochromic inks also allow a can to change color when exposed to sunlight – so a manufacturer could hide a message within the can that can only be revealed under the right set of circumstances.

These innovations provide a new experience and open up a whole world of marketing opportunities for big and small beverage brands alike. We’re seeing these innovations being used more and more across multiple markets – from beer to soda to energy drinks and to canned cocktails, brands need to get creative with packaging if they want to compete.

However, while the opportunity may be rich, it also opens up a whole new world of quality issues for manufacturers.

As packaging becomes more sophisticated, it’s more important than ever to have the highest quality of equipment in place to tackle all issues – having the best headspace analysis, leak detection, and seam inspection instruments is clearly critical.

But it’s also so important to ensure investment in the appropriate systems to carry out sophisticated coating checks, the best label inspection instruments to achieve consistency, and instruments to ensure the durability of cans during transportation. Because when innovation within packaging is being explored, there’s extra room for mistakes to spill through the cracks.

As a packaging manufacturer, you need to be prepared.

Discover our beverage test and inspection solutions here!

Light weighting in cans to reduce material use

It’s not just aesthetically driven motivations that are encouraging manufacturers to innovate when it comes to beverage packaging.

As mentioned earlier, a desire for more eco-friendly packaging is leading to huge innovation across the beverage packaging space.

And the light weighting of both steel and aluminium cans is a huge cause of disruption across the industry.

The benefits of creating lighter weight cans are multifaceted – first and foremost, using less material obviously has advantages from a sustainability perspective. Producing a lighter weight can means using less material, which ultimately results in an eco-friendlier package.

CO2 emissions from aluminium production in drinks cans in Europe reduced from 31% from 2006 – 2016 – largely thanks to a reduction in material usage.

Across Europe, over the last 25 years the weight of steel and aluminium cans has reduced by one third.

While becoming greener is a huge advantage for manufacturers, it’s important to recognize that the reduction in materials can also have huge cost saving implications when we look at cans produced at scale. So, there are numerous benefits at play here.

However, as with any type of disruption to the norm within packaging, the impact on quality control must be considered. This desire to utilize less materials challenges manufacturing systems and requires closer process control.

Making cans lighter while still retaining their strength, ensuring material reduction doesn’t introduce damage, and determining new risks associated with light weighting are all key components for consideration. As a result, rigorous testing becomes even more critical.

The increase of metal packaging 

How is the increase of metal packaging disrupting the beverage space?

The age of metal packaging

For so many different reasons, beverage manufacturers across multiple markets are switching things up and opting for metal packaging solutions - increasing their investment in this packaging route.

There are more types of drinks being canned than ever before!

From CBD infused beverages to flavored water, and from pre-made cocktails to canned wine, the canned beverage space is spilling over.

Numerous beverage brands are opting for metal – gone are the days when beer and soda were the only drinks you’d expect to find fizzing away in a metal can.

There are huge differences in the rate of adoption across the globe though. Take Germany – a country that was relatively new to the metal packaging boom.

Over the past five years, the sale of beverage cans has risen from 2 billion to 4 billion - a short space of time for such a dramatic increase.

So, why are geographies and drinks markets that were previously less keen on metal packaging adopting this route now?

The metal cans market was valued at USD 53.37 billion in 2020 and is expected to reach USD 61.37 billion by 2026, registering a CAGR of 2.23% over the forecast period (2021 - 2026)

A more sustainable option

It goes without saying that metal packaging offers high recyclability, and as so many beverage brands seek to go greener, the canning of drinks seems like an obvious step in the right direction.

Making products from recycled materials allows manufacturers to use less energy, reduce carbon emissions, and also use less water compared with raw materials.

"A significant amount of the valuable aluminum in beverage cans is recycled since aluminum beverage cans are the most recycled beverage packaging in the United States and the world. In fact, in 2019 in the United States, there were more than 40 billion aluminum beverage cans recycled, the equivalent of 11 12-packs per person.

The vast majority of the beverage cans that are recycled are turned into new cans making it the textbook example of the circular economy.

This is how the recycled content of aluminum cans in the United States averages a whopping 73 percent."

Scott Breen, VP of Sustainability for the Can Manufacturers Institute

An increase in quality control 

Ultimately, a lot of beverage manufacturers have moved away from bottles and started exploring more options with metal packaging.

In this instance, a lot of companies who never had a need to invest in testing instruments for canning now find themselves needing to find a whole new range of instruments.

In this situation, it’s crucial to find a partner with the right expertise - someone who can support you in finding exactly the right equipment for your unique needs.

For those dealing with metal packaging for the first time, the potential for issues within quality is huge.

It's critical to have accurate and easy to use equipment that takes the guesswork out of quality checks and machinery set up.

What impact has the pandemic had on beverage packaging?

The pandemic has ushered in an era of uncertainty that all industries have felt in different ways. But what has the pandemic meant for packaging manufacturers within the beverage space?

Unsurprisingly, there’s been a marked increase in the amount of home deliveries of beverages – and this also has an impact on quality control. It’s important that manufacturers and production lines are readying themselves for nuances to deliveries and shipping expectations.

Having the right test and inspection instruments that can prepare your packaging against any turbulent journeys is a sometimes forgotten but exceptionally important investment – now more than ever.

"The change in consumer behavior toward more home-based activities has driven demand for existing and new packaged beverages that were previously consumed in the office, restaurants and other retail spaces.

Teas, juices, coffee, enhanced water, and carbonated flavored waters have all gained market share."

John Cullen, Director of PET resins sales and marketing for DAK Americas LLC

Across the board, there’s been a marked increase in the demand for smaller sized containers sold in multipacks, as well as in a larger size. There’s also been a reduced demand for mid-sized containers.

Ultimately though, one of the biggest trends facing manufacturers is the unknown.

Within the context of the pandemic, consumer habits are changing quite literally on a daily basis as circumstances continue to shift.

Predicting the long-term future impact of the pandemic in relation to beverage packaging is a complicated task.

But there is one thing that we can be sure of – and that is the importance of flexibility and adaptability.

As manufacturers and production lines continue to navigate the ever-changing circumstances, it’s important to be expecting the unexpected, and the ability to pivot and react to new trends within your packaging processes will allow you to stay ahead of the curve.

And in order to stay flexible and mix things up at a moment’s notice, an investment in test and inspection is not a luxury. It’s a necessity.

As experts in seam inspection, we're here to offer advice around the best solutions for your seamer set up. Our resident expert, Steve Davis, offers advice!

Check out our advice around can inspection!

Quenching your thirst for perfection

Now, more than ever, investing in the right test and inspection instruments is critical. You can learn about our array of solutions developed for the beverage industry here.

Our instruments have been designed to ensure you receive the highest quality solution, exceptionally accurate results, all while reducing your costs and saving you time. So, how does this work exactly? 

We analyzed our SEAMscan XTS system against traditional destructive seam inspection systems to offer you insights into how our solutions save you time and money. 

If you'd like to speak to us directly about the benefits of a different system, or you'd like more information about any of our solutions, feel free to get in touch!

Save time.

Based on reduction of inspection time at a beverage facility after change to non-destructive testing.

• Cans tested: 12
• Inspection time to measure 12 cans (3 locations) with tradntional destructive testing = 35-50 minutes (depending on operator)
• Inspection time to measure cans using SEAMscan XTS = 15-20 minutes
• Benefits = money saved during operation, a more efficient process, reduced labor costs

Total reduction in inspection time: 65%

Save money.

Based on reduction of package spoilage at beverage facility after change to non-destructive testing.

• Cans tested: 288 per day (four 12-head seamers with cross-section test made every 4 hours, running 24 hours a day)
• Production days: 350 days per year
• Customer valuation of filled can: $1.00 per can

Total savings: $100,000 per year

NB: cost savings do not include additional cans destroyed for re-checks/line set up and adjustment.

At Industrial Physics, we’ve been providing test and inspection solutions to manufacturers, production lines, and laboratories across the world for almost 100 years. It’s our purpose to protect the integrity of our customer’s brands and products.

How do we do this? By providing the highest quality of test and inspection solutions that assure the quality of your packaging, materials, and products.

But for us, this is about more than just supplying you with testing equipment, it’s about being there for you as a full-solutions partner. Whatever your needs are, we’ll work with you to find the right option for your business.

We have a full team of experts to support you.

And when it comes to quality control within the beverage market, we know our stuff. We offer a full suite of solutions to cover an extensive range of testing requirements to ensure perfection in beverage packaging.

It's our innate desire to continuously learn, innovate, and better ourselves that allows us to provide businesses across a diverse range of industries with the highest quality of test and inspection solutions possible.

Our experts are positioned across the world. And through our collective expertise, we're able to support the unique needs of our customers.

"Our brewery has experienced great customer service with Industrial Physics. As a Chemist, I understand equipment doesn’t work all the time.

The technical support team for Industrial Physics have made sure that when equipment needs support, it is done right away.

We have experienced very minimal downtime due to their dedication! I can’t express enough how happy I am with their support!"

Gicole Patterson, Blues City Brewery

Get in touch with our team!

At Industrial Physics, we believe that supplying you with high quality testing instruments is only part of our job.

We’re committed to offering you a service that ensures your needs are fully supported throughout every step of your journey with us – from purchasing, to installation, and throughout ongoing maintenance.

We understand that being fast, efficient, and truly reliable is critical when it comes to servicing the instruments that keep your business running. And that’s why we’ve established a global network of dedicated service specialists – to ensure you have an expert ready and waiting at a nearby location who can offer you support.

Wherever you are in the world, our experts are on hand to support your needs – whatever they may be. We know that having the right people ready to help is critical. It’s critical to delivering a quality and speedy service that ensures your instruments can get up and running as quickly as possible. From installation, through to calibration, repair, and preventative maintenance, we’ve got you covered.

Our service options are truly diverse, and we also offer comprehensive training and dedicated support so that you can make the most of your machines. If you want to find out more about how we can help you, just get in touch.

Get in touch today!