Food packaging is the last barrier between the product and contamination. Seal failures, migration of harmful substances, and labelling errors (allergens, expiry dates) can cause illness, allergic reactions, or death. Food safety authorities enforce strict controls.
AQL levels range from 0.065 for critical seal and contamination defects to 1.0 for cosmetic packaging issues. HACCP, BRC, and FDA FSMA require documented sampling plans as part of the food safety management system.
| Defect Type | AQL | Inspection Level | Notes |
|---|---|---|---|
| Critical (seal, contamination) | 0.065 | Special S-4 | HACCP critical control point |
| Major (label, allergen info) | 0.15 | General II | Regulatory compliance |
| Minor (print quality, colour) | 1.0 | General I | Brand appearance standards |
AQL 0.065 inspection found micro-leaks in 0.3% of retort pouches. The batch was rejected before filling, preventing potential botulism contamination in 100,000 ready-meal units.
Pre-shipment AQL 0.15 check confirmed all packaging correctly declared peanut allergens in 12 languages, ensuring compliance across EU markets.
Missing allergen declaration on 50,000 snack bar wrappers led to a Class I recall after three hospitalizations. Total cost exceeded $8 million including legal settlements.
