Compressive Burst

Compressive burst testing is a specialised method for determining the maximum internal pressure a container can withstand before structural failure. This process is vital for verifying the integrity, safety, and durability of containers used to store liquids or gases. It ensures that products can withstand pressures experienced during filling, handling, storage, and transportation.

Industries such as packaging, food and beverage, pharmaceuticals, and chemicals depend on burst testing to validate designs, meet regulatory requirements, and maintain consumer safety. Burst resistance is especially important in pressurised products such as aerosols, carbonated beverages, medical oxygen canisters, and flexible pouches subject to inflation.

The test involves applying a controlled internal pressure to a container until it fails. The burst pressure and failure mode are recorded for analysis. The choice of method, compliance with standards, and the accuracy of the equipment determine whether results are meaningful and repeatable.

Inflationary burst testing

In this method, internal pressure is gradually increased using air, gas, or liquid until the container ruptures. This is widely applied to:

• Flexible packaging, such as pouches or bags, to assess seal strength and film durability
• Rigid containers, such as bottles, jars, and aerosol cans, to confirm structural limits

Key features of inflationary testing:

• Gradual pressure increase simulates real-world conditions
• Burst pressure and rupture location are recorded
• Can be run as a destructive test to failure or as a non-destructive proof pressure test

This approach closely replicates service conditions for pressurised products and allows detailed analysis of material and seam weaknesses.

Platen compression burst testing

For some rigid containers, compression between platens is used to induce failure. This method evaluates overall crush resistance but does not replicate the effects of internal pressurisation as accurately as inflationary testing.

Testing seam integrity

A container’s seams are often its most vulnerable points. Seam testing evaluates how well these joints withstand internal pressure without leakage or rupture.

Applications include:

• Aerosol cans - assessing the double seam between body and lid
• Flexible pouches - testing the strength of heat seals
• Bottles and jars - checking closure seals under internal expansion

Seam testing can reveal manufacturing defects, material inconsistencies, or degradation over time. For example, in aerosol production, burst testing identified premature seam failure in certain batches due to incomplete seam roll formation. Adjusting machinery settings resolved the defect and improved product reliability.

BS EN ISO 8670-2 specifies methods for testing pressurised containers, including procedures for determining the pressure at which a container fails. It ensures testing is consistent, repeatable, and conducted safely.

Other relevant standards may include:

• Packaging performance tests for transport safety
• Industry-specific methods for food, beverage, and pharmaceutical containers

Best practices for burst testing:

• Condition samples to specified temperature and humidity before testing
• Use calibrated equipment for accurate measurement
• Record burst pressure, rupture location, and failure mode
• Perform statistical analysis across multiple samples for quality verification

The right equipment depends on the container type, material, and applicable standard.

• Pneumatic burst testers - Apply controlled air or gas pressure internally, suited to flexible and rigid containers
• Hydraulic burst testers - Use liquids to pressurise containers, reducing risk from explosive ruptures
• Mechanical compression systems - Apply platen-based force to measure crush resistance

Essential equipment features:

• High-resolution pressure measurement for precise burst determination
• Adjustable fixtures to accommodate different shapes and sizes
• Data acquisition software for automated recording and analysis

Key metrics include:

• Burst pressure - The maximum internal pressure before failure
• Failure location - Identifies weak points in design or manufacturing
• Deformation pattern - Indicates material flexibility and strength distribution

Results may be used to:

• Adjust material specifications for improved durability
• Modify seam or closure designs
• Validate packaging for regulatory compliance

For example, a beverage manufacturer improved PET bottle burst resistance by increasing wall thickness in critical areas, without significantly increasing material use.

Mecmesin designs and manufactures precision test systems to meet the demands of compressive burst testing.

• OmniTest single-column testers - Ideal for small containers and lower-capacity burst tests
• OmniTest twin-column testers - Suitable for high-capacity testing of large or heavy containers
• MultiTest-dV - Cost-effective and accurate for routine production testing
• VectorPro software - Provides real-time data capture, graphical analysis, and automated reporting
• Custom fixtures - Developed to suit a wide range of container shapes and test standards

All Mecmesin systems are standards-compliant, delivering accurate, repeatable, and traceable results for industries from food and beverage to pharmaceuticals.

Compressive burst testing is critical for ensuring container safety, durability, and compliance. By applying the right method, following recognised standards such as BS EN ISO 8670-2, and using precision Mecmesin equipment, manufacturers can confidently assess burst resistance and improve product performance.

Contact our technical team to discuss your testing requirements, choose the right fixtures, and configure a system that delivers accurate, repeatable, and compliant burst testing.