Hidden Costs of Using Poor Sealing Films

Unexpected Damages When Using Poor Seals

Although it’s a small component of packaging, the sealing film is a key factor in maintaining product quality. Before discussing the risks of poor sealing, let’s clarify what sealing films are and the types commonly found on the market.

What Is a Sealing Film?

A sealing film is a thin layer, typically made of aluminum, plastic, or a combination of multiple materials. Its main purpose is to line or tightly seal the container opening, protecting product quality.

Essential Standards for Sealing Films

A proper sealing film must meet specific technical criteria to ensure the best performance.

Adhesion strength: The seal must firmly adhere to the container mouth and not peel off during transport. It should be easy to open without damaging aesthetics or product quality.
Heat resistance: The film must withstand heat during the sealing process without burning, warping, or losing airtightness.
Safety and non-toxicity: The film should comply with safety standards (ISO, GMP) and not release harmful substances, heavy metals, or odors that affect the product.

Consequences of Poor Sealing

Hygiene and Safety Issues

Sealing films act as a barrier preventing air, dust, and bacteria from contaminating the product. When the seal fails to meet standards, this barrier is compromised, leading to oxidation, spoilage, or microbial growth.

For food products, poor seals can cause leaks, mold, or spoilage. For pharmaceuticals, the active ingredients may degrade, posing health risks to consumers.

Economic Losses

Using poor seals increases the rate of defective products, forcing companies to recall, replace, or destroy entire batches, raising production costs and damaging brand reputation.

If products are returned from distributors, the company also suffers additional logistics and warehousing costs.

According to a 2025 FDA report, three lines of functional honey products from Commita Company were recalled due to improperly installed induction seals. The faulty seals caused honey leakage and reduced product safety. FDA classified the incident as Level II, indicating potential health risks. The company had to recall products across seven U.S. states, suffering millions of dollars in losses.

>>> Read more: Thousands of Manuka Honey Products Recalled Due to Faulty Seals

Legal Risks

In the food, pharmaceutical, and cosmetic industries, packaging materials must meet strict safety regulations. If a product is found to use non-compliant sealing films, the company may face fines, license suspension, or product bans severe risks when consumer health is involved.

Brand Reputation Damage

Consumers are increasingly conscious of product safety and quality. Even a few negative reviews about leakage, spoilage, or weak seals can destroy a brand’s credibility. Once trust is lost, regaining market share becomes extremely difficult.Many companies believe that choosing cheaper seals saves costs. In reality, this “saving” creates multiple hidden costs. When products spoil due to poor sealing, businesses face extra expenses for recall, repackaging, or disposal.

Defective goods also interrupt distribution schedules, adding logistics, storage, and labor costs. Worse, if consumer health is affected, companies may incur compensation or legal costs. The initial savings from low-quality seals often turn into losses many times higher later on.

Causes of Poor Sealing Quality

Low-Grade Materials

The most common cause is using unqualified or recycled materials to reduce costs. Recycled aluminum or plastic weakens durability, making the seal prone to tearing or puncturing.
Poor-quality adhesives can lose grip or contain toxic chemicals (heavy metals, solvents) that contaminate food or medicine directly endangering consumer health.

Wrong Seal for the Product

Each product type requires different sealing properties:

Oil or grease-based products: need moisture-resistant seals; paper seals can peel or deform.
Powder products: require tight seals to prevent powder leakage.
Chemical liquids: may corrode or weaken the sealing material.
Additionally, the seal must be compatible with the container material (PET, PS, PP, glass). Using the wrong combination leads to weak adhesion and air leakage.

Errors in the Sealing Process

The temperature, pressure, and sealing time must be precisely controlled.
Low heat: adhesive doesn’t melt properly, causing weak bonding.
Excessive heat: burns or warps the film.
Uneven pressure: creates air gaps or swollen seals.
Old or poorly maintained sealing machines further worsen consistency and quality.

Counterfeit and Substandard Seals

The market is flooded with cheap, unverified sealing films lacking certifications or safety labels. These low-cost options are often thin, tear easily, and lack anti-counterfeit features (logo, serial number).

Such products are not FDA or ISO certified, posing potential legal violations. Using them not only risks product quality but also damages brand integrity.

Comprehensive Solution from Sam Lan

To ensure maximum product protection, Sam Lan provides internationally certified sealing film solutions (QUATESTPP, QUATESTPSP, QUATESTEPE, etc.).

Premium materials: Made from certified safe materials with strong adhesion, mold resistance, and microbial protection.
Strict quality control: All products are manufactured under ISO standards, ensuring global compliance and facilitating export market access.
Professional technical support: Our team of engineers and experts offers end-to-end guidance from material selection to sealing process optimization minimizing technical risks and ensuring consistent product quality.
With Sam Lan, businesses gain not just sealing films but a complete protection solution enhancing product safety, competitiveness, and long-term brand sustainability.

Conclusion

Sealing films may seem small, but they are vital to product safety, quality, and brand trust. Using poor-quality seals doesn’t just cause leaks or spoilage it triggers massive hidden costs, legal risks, and reputational damage.

Investing in high-quality sealing from the start can save millions and safeguard your brand’s reputation. The cost of poor sealing is always far greater than the initial investment. Contact Sam Lan today to choose certified, reliable sealing solutions.