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The films and flexible packaging sector is evolving fast. Tighter tolerances, greater scrutiny and complex supply chains are exposing the limits of traditional quality tools. As manufacturers seek accuracy without slowing production, smarter, safer alternatives are emerging. Vivek Komaragiri, principal technologist at Industrial Physics, explains why reliance on nuclear gauges is reaching its limit – and how advanced optical systems are enabling sharper quality control, leaner operations and a more resilient future for converters and brand owners.

For decades, food and beverage packaging professionals working with films and flexible substrates have relied on nuclear gauges to measure coating thickness. This approach, built around radioactive sources such as Promethium, Krypton and Strontium, once represented the only viable way of ensuring coatings met the specifications required for product performance, safety and shelf stability.

But the ground is shifting. Obtaining and maintaining nuclear sources is getting increasingly challenging to manage, with geopolitical risk, financial burden, regulatory scrutiny and practical limitations taking their toll on the professionals responsible. At the same time, many are unaware that highly effective non-nuclear alternatives exist, leaving them to assume that if nuclear gauges are unavailable, quality assurance becomes impossible.

This is a misconception that must be addressed. As the pressures surrounding nuclear gauges continue to grow, it is increasingly important for packaging professionals to be aware of alternative approaches.

A growing set of obstacles

For decades, nuclear gauges have been the backbone of coating thickness measurement. But today, professionals are encountering a series of mounting challenges. Nuclear sources deteriorate over time, requiring replacement every few years, which not only reduces accuracy but creates ongoing procurement pressures. Geopolitical disruption has made sourcing nuclear materials more complex and costly, with longer lead times and uncertain availability.

Safe disposal presents further obstacles. Strict protocols demand secure transport and storage, yet established disposal pathways are tightening under increased scrutiny. The financial implications are equally significant: replacement sources can cost upwards of six figures, at a time when raw material and energy prices are already placing pressure on margins. Add to this the burden of regulatory compliance and administrative oversight, and the case for persisting with nuclear gauges is becoming harder to justify.

Perhaps most importantly, nuclear gauges are struggling to keep pace with the industry’s own innovations. As coatings become thinner and more sophisticated, measurement precision is compromised by the inherent limitations of decaying radioactive sources.

The non-nuclear alternative

The perception that nuclear gauges are the only viable method of thickness measurement is increasingly outdated. Advances in optical physics have enabled the development of non-nuclear solutions that not only eliminate reliance on radioactive sources but also deliver higher precision and flexibility.

Optical interference technology, for example, measures coating thickness by directing light onto a material and analysing the interference patterns created as it reflects through different layers. This non-contact, non-destructive approach allows for absolute thickness measurement without the need for radioactive material, calibration with every coating change or extensive operator oversight.

What makes this technology especially valuable to food and beverage packaging is its ability to measure extremely thin coatings with consistency. As manufacturers experiment with lightweight laminates, oxygen barriers, UV coatings and other advanced films, measurement precision becomes essential to ensuring both performance and compliance. Unlike nuclear gauges, which lose accuracy as sources decay, optical systems deliver consistent results over time, enabling continuous, reliable quality assurance.

Equally important is the ease of integration. Non-nuclear systems are designed with modularity in mind, meaning they can be fitted into existing lines without major disruption. By storing data digitally and feeding it into statistical process control systems, these solutions also create a richer quality record that can be used for predictive maintenance, process optimisation and easier resolution of customer claims.

Unlocking broader benefits

The advantages of moving away from nuclear gauges extend beyond compliance and risk reduction. Non-nuclear measurement systems help manufacturers achieve higher levels of accuracy, even at sub-micron thicknesses, enabling them to meet the evolving demands of modern packaging design. This precision reduces rework and waste, ensuring that raw materials are used more efficiently and production batches meet specifications the first time.

Operational efficiency is another clear benefit. Because optical systems do not rely on decaying sources or constant recalibration, they allow production to continue with fewer interruptions. Switching between coatings or substrates is faster and simpler, giving teams more flexibility in managing shorter production runs or rapidly changing customer requirements.

There is also a sustainability dividend. Non-contact, non-destructive testing preserves samples and reduces scrap, while optimised coating control lowers energy and solvent consumption. In an industry under pressure to demonstrate measurable progress on environmental goals, these gains can be meaningful.

Finally, the digital nature of non-nuclear systems allows manufacturers to generate and store a complete record of their coating data. This not only strengthens traceability and accountability but also opens the door to predictive analytics. Over time, patterns in the data can highlight opportunities for preventive maintenance or process improvement, creating a feedback loop that supports both operational resilience and long-term cost efficiency.

The next chapter

The food and beverage packaging sector is evolving quickly, with thinner coatings, complex multilayer structures, and rising expectations around quality and sustainability. In this context, nuclear gauges are becoming increasingly difficult to justify, not only because of the challenges of sourcing, cost and compliance, but because they are no longer the most effective tool available.

Non-nuclear measurement technologies provide a practical and forward-looking alternative. They deliver higher accuracy, integrate seamlessly into existing operations and generate the digital insights needed for continuous improvement. Just as importantly, they help reduce waste, enhance sustainability and protect margins at a time when efficiency matters more than ever.

For professionals in films and flexible packaging, the choice is no longer between persisting with a legacy approach or going without measurement. There is a third path - one that replaces radioactive sources with optical precision, reduces operational risk and strengthens the foundation for innovation. By exploring non-nuclear solutions today, manufacturers can ensure their coating measurement practices are not only fit for purpose but fit for the future.