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🎯 The Challenge: Unexplained Failures Post-Distribution
A Chennai-based packaging supplier started facing complaints:
Food sachets puffed up prematurely
Films discolored under storage
Seal integrity failed within 30 days in humid retail shelves
The material passed visual QC and tensile tests. But one thing hadn’t been tested: humidity resistance.
🔍 Diagnosis: Moisture Barrier Weakness
The team collaborated with a local NABL-accredited testing lab. Over a 3-week test program, they ran:
MVTR testing (ASTM F1249): Showed >20 g/m²/day, too high for intended shelf life
Accelerated aging under 85% RH, 40°C: Revealed delamination and seal creep
ASTM D2126: Confirmed dimensional instability due to absorbed moisture
🧪 The Fix: Better Testing, Better Material Design
Armed with data, the team switched to:
A multilayer film with EVOH barrier
Moisture scavengers in the inner sealant layer
Updated specs with MVTR < 3 g/m²/day
They also made humidity resistance testing part of their QA plan, including:
Since the change:
✔ No product complaints from humid zones
✔ Improved export compliance (EU, ASEAN)
✔ Shorter troubleshooting cycles thanks to archived humidity data
📘 Key Lessons for Manufacturers
Humidity testing is preventive—not reactive
Test to the climate of your customer, not just your factory
Use local Chennai labs—they understand the city’s real environmental stresses
Involve humidity tests early in R&D and packaging design
💬 Final Word
In Chennai’s climate, it’s not a question of if humidity will affect your material—it’s when.
Are your plastics and rubbers truly tropical-ready? The right test today can save your brand tomorrow.
Let me know if you’d like to turn this story into a downloadable case study PDF or a LinkedIn post series!