Quality in packaging is not an inspection that happens at the end. It is a reference agreed at the sample stage, then checked at several points on the way to the carton. This is what we measure, and what the numbers mean.
At a glance
- Inspection standardAQL General Inspection Level II
- AcceptanceCritical 0 · Major 2.5 · Minor 4.0
- Functional testsSealing / leakage · torque · drop · printing and coating adhesion
- DocumentsSGS raw-material reports · REACH-related reports · PPWR-related testing documentation
- ReferenceThe approved sample and the confirmed specification
What the acceptance levels mean
| Class | What falls into it | Accepted |
|---|---|---|
| Critical | Anything that makes the item unsafe or unusable — leakage, a closure that will not hold, a part that cannot be assembled | 0 |
| Major | A defect a buyer would notice and reject — colour off the approved chip, missing print, a scratched sprayed surface | 2.5 |
| Minor | A deviation that does not stop use or sale — dust, a light flow mark in an inconspicuous area | 4.0 |
The four tests, and what each one catches
| Test | Catches | Runs on |
|---|---|---|
| Sealing / leakage | A tube, jar or bottle that will not hold its fill in transit or on the shelf | Filled or simulated-fill items, where applicable |
| Torque | A cap that loosens in the carton, or one the consumer cannot open | Threaded closures |
| Drop | Material that cracks, or a mechanism that fails on impact | Item in its retail packing |
| Adhesion | Print or coating that lifts with tape, abrasion or an alcohol wipe | Decorated surfaces |
From raw material to the carton
- Incoming materialResin and components checked against the specification before they enter production.
- First articleThe first parts off the machine are compared with the approved sample — before the run continues.
- In-lineDimension, appearance and decoration position checked during the run, not collected for the end.
- Final inspectionFinished goods sampled to AQL Level II with the levels above, plus the functional tests that apply.
- Before dispatchCartons, quantities, labels and packing method confirmed against the order.
What we need from you
- Your own protocol, if you have one. Send it before production so it can be written into the order. A standard introduced after the goods are made cannot be inspected retroactively.
- The critical dimensions — the two or three measurements your filling line depends on. Everything else carries a tolerance; these may not.
- Filling-line constraints: cap torque range, tube length for your filler, a decoration area that must stay clear for a batch code.
- Market requirements: restricted substances, sustainability or packaging-waste rules. See the compliance question.
If something arrives wrong
Send photos, video, affected quantities, carton or batch information and a clear description. We trace it back through the production and QC record, agree a solution — sorting, replacement, remake or another corrective action — and fix the cause. The full answer is in the after-delivery question.
AQL is a sampling standard, not a promise of zero defects. Level II at 0 / 2.5 / 4.0 describes the probability a lot is accepted at a given defect rate. If your product cannot tolerate any cosmetic deviation on a visible surface, say so: that becomes a 100% visual sort on that surface, priced and scheduled as its own operation.
Have a specification sheet or a QC protocol to send? Start a project and attach it — we will answer against it.