The evolution of testing technology is presenting manufacturers with opportunities to build resilience, optimise production and protect brand integrity. But what do these technological advances mean in practice, and how can operations adapt intelligently? Here, Stefan Welker, strategic segment manager, rigid packaging at Industrial Physics, shares his insights.

As metal packaging manufacturers navigate increasing complexity, from global supply chain disruptions to sustainability targets and skilled labour shortages, quality assurance has taken on renewed strategic importance.

While compliance remains a baseline requirement, many in the industry are beginning to see quality testing differently: not as a gatekeeper, but as a gateway. As a result, many are shifting away from traditional quality control, where the product is viewed as a control point, toward strategic investment in safe and stable manufacturing processes.

Shifting priorities

Industrial Physics’ recent global research series examined key areas including internal pressures, external factors and testing innovations. The data highlighted a clear industry trend: more than 75% of packaging professionals were actively exploring ways to modernise their testing processes, with a particular focus on integrating automation and real-time inspection into operations. The rationale is clear. Manufacturers are being asked to do more with less – less material, fewer people and tighter timelines – but with no compromise on quality.

In fact, 82% of respondents reported having been impacted by supply chain delays within the year. In parallel, internal challenges are also mounting. Over half of professionals questioned cited reduced team sizes or staffing changes as key concerns, intensifying the pressure to deliver quality outcomes with leaner resources. In response, many manufacturers are rethinking their approach to quality testing. Not simply by automating tasks, but by building deeper visibility and control into their processes.

Quality testing as a proactive tool

Traditional quality testing has often been seen as a final checkpoint. But modern systems allow manufacturers to identify defects and deviations far earlier in the manufacturing process, enabling intervention before waste is created or product integrity compromised.

Take the use of automated seam inspection systems, for example. These technologies can now be directly integrated into the production line, automatically sampling cans and analysing seam quality. The results are directly linked to specific seamer heads, enabling manufacturers to pinpoint issues faster and eliminate the need for protracted shutdowns during routine checks. The result is higher product quality, reduced downtime and greater operational confidence.

Similarly, bead profile analysis in 3-piece can production has evolved. Continuous sampling allows operators to detect roller misalignment or wear in real time. By monitoring these trends, manufacturers can make precise adjustments that improve axial load capacity - an outcome that not only improves safety and performance but also supports material reduction initiatives by validating the strength of thinner walls.

Targeted reduction in resources

One of the clearest advantages of advancing testing technology is its ability to support manufacturers in achieving a targeted reduction in resources: a concept that spans materials, energy, labour and time.

In terms of material savings, automated testing allows manufacturers to confidently explore downsizing without risking structural integrity. For example, precise measurement of score depth on easy-open ends ensures the lid performs as intended – easy to open, yet strong enough to withstand the internal pressure during pasteurization or in the heated car of the end consumer. The ability to test this parameter consistently and accurately supports reductions in raw material use, without introducing product failures.

On the labour side, automated systems reduce the need for manual data collection. Where previously operators might have performed spot checks and manual measurements, modern systems can load, test and return samples to the line, freeing up skilled staff to focus on higher-value tasks. This becomes especially critical as workforce reductions and hiring challenges persist.

There are also opportunities in process efficiency. Inline monitoring of the coolant in bodymakers, for instance, prevents contamination buildup and potential machine failures by detecting and reacting to trends before problems occur. In many cases, this proactive approach avoids costly downtime and tool damage.

All these strategies contribute to a reduction in resources and cost savings. Importantly, they also create a framework for scalable, sustainable manufacturing that doesn’t trade off on quality.

The power of statistical process control

The growing adoption of Statistical Process Control (SPC) systems is another marker of progress. These tools don’t just collect data, they contextualise it. By comparing quality metrics against machine performance, material inputs and environmental conditions, SPC applications allow for predictive maintenance and trend-based process improvement.

In can making, this means being able to track and correct variables like wall thickness, coating weight and colour uniformity, with unprecedented precision. For instance, non-contact coating thickness measurement at the coil stage ensures coatings are applied within specification, minimising waste and ensuring downstream performance.

Over time, manufacturers that invest in these capabilities position themselves for stronger customer trust, improved efficiency and greater agility in responding to regulatory change.

Considerations

For those looking to advance their testing capabilities through the strategic implementation of modern technology, several questions are worth asking:

·         Where are your current bottlenecks? Identify where most of your quality-related downtime or waste originates.

·         How is quality data collected and who analyses it? If your data is still siloed or manual, opportunities likely exist to integrate and automate.

·         Can your current systems scale with your sustainability goals? Material savings often require more precise process control, not just different materials.

·         Are you reacting to problems or predicting them? Trend analysis tools allow you to act before quality issues emerge.

Ultimately, the goal isn’t just to digitise what’s already being done, but to reimagine what’s possible with the right information in the right hands, at the right time.

Beyond compliance: The strategic value of quality

Technology will not replace the need for quality assurance in metal packaging, but it is transforming what quality assurance can deliver. From greater resource efficiency to enhanced customer confidence, the benefits extend beyond compliance.

Manufacturers that treat quality testing as a strategic lever, rather than a necessary cost, will be better equipped to navigate uncertainty, optimise their operations and unlock new forms of competitive advantage.

Source：AL Circle