Increased Demands for Non-destructive Leak Detection In 2026

Why Retailers Are Demanding More Data On Leak Detection and Seal Integrity Testing

In 2026 there will be a step‑change in compliance expectations for MAP producers, to further reduce waste, which effectively mean:

• Leak detection must be validated, documented, and defensible
• In many cases, destructive manual water bath testing will only be accepted as a secondary test
• Extended shelf life must be supported by seal‑integrity evidence

The MAP market has been aware for some time now, of a significant increase in the expectations and requirements of major retailers. In part, this may be being instigated by the Packaging and Packaging Waste Regulation (PPWR) – Regulation (EU) 2025/40, which legally comes into effect on 12th August 2026.

Although there is no specific MAP leak detection regulation included, the regulations create legally enforceable design and performance obligations, that cannot be met without verified seal integrity. And while the UK is no longer a part of the EU and will, therefore, not automatically adopt the PPWR, we know that UK food‑safety regulations will closely follow many of the changes and expectations.

The new legal obligations that affect MAP, include:

1. Packaging must maintain functionality throughout its intended life
   • Packaging must protect product quality, safety, and shelf life
   • Gas‑barrier performance must be demonstrably maintained
   • Seal failure = non‑compliance

For MAP food products, this implicitly requires validated leak detection rather than visual inspection only.

2. Recyclability and material minimisation
   • Thinner films and mono‑materials are encouraged
   • Reduced material use increases seal sensitivity
   • Regulators expect controlled sealing and leak verification

Many legacy water‑bath tests will now be considered insufficient as the sole test for MAP films.

3. Increased enforcement under food‑contact legislation
   The PPWR works alongside the EU Food Hygiene Regulation (EC) 852/2004 and the General Food Law Regulation (EC) 178/2002. From within these, regulators increasingly view undetected MAP leaks as:

• • A food‑safety failure
  • A misleading shelf‑life claim

What This Means for UK Packaging Lines

• Leak detection must be validated, documented, and defensible
• In many cases, manual water bath testing only will no longer be sufficient
• Extended shelf life must be supported by seal‑integrity evidence