Blister packaging · Industry glossary
Channel leak
A continuous leak path through a seal region between joined packaging materials.
Also called: seal channel; seal leak channel; channel leakage.
What is a channel leak in a blister seal?
A channel leak is a continuous leakage path across the seal region between joined materials. A pinhole passes through material instead. Identify the path and affected boundary rather than using the two names interchangeably.
A wrinkle or line visible in a seal is an observation to investigate, rather than proof by itself of a continuous path. Describe whether communication across the seal was demonstrated instead of using “channel leak” as a synonym for every cosmetic seal mark.
| Finding | Distinction to establish |
|---|---|
| Material pinhole | Which layer is penetrated, and whether the hole goes through the complete structure. |
| Seal channel | Whether a continuous path crosses the seal between the joined materials. |
| Unlocated package leak signal | Leakage was indicated, but the path has not yet been identified. |
Does a dye-test result tell you the channel size?
Not from a qualitative leak-location result alone. Evidence that dye has travelled through a seal path identifies an observed passage under the test conditions; it does not quantify the channel’s size. Keep edge-seal channels distinct from holes in flat material.
Method capability and measured defect size are different quantities. Interpret a dye result within the method’s applicable package constructions and test conditions.
Detecting a leak vs locating its path
A leak signal and a located channel answer different questions. Check whether the result covers an entire pack or an identified area, and whether the method actually located the path rather than only detecting leakage.
Seal strength measures resistance to separation. It can complement a leak investigation, but cannot locate the path through which leakage occurred.
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