DIN 53380 Testing of Plastics - Determination of Gas Permeability

The standard “DIN 53380 Testing of plastics - Determination of gas permeability”, published by the German Institute for Standardization (DIN), consists of the following sub-sections published under the same title:

• The method described in the standard “DIN 53380-1 Part 1: Volumetric measurement method for plastic films” is used to determine the velocity of gas (e.g., oxygen, carbon dioxide, nitrogen, and mixtures thereof) passing through a plastic film and, consequently, its suitability for packaging, for example, sensitive products. This method cannot be used for gases that tend to condense or chemically react with the sample material.

Gas flow rate is measured by determining the volume of gas passing through the sample under specified conditions. Those given in Clause 8 are suitable for determining gas flow rates ranging from approximately 3 cm³/(m²•d•bar) to 20000 cm³/(m²•d•bar) (d is the symbol for days). Since the gas flow rate depends on the thickness of the product, reproducible results can only be obtained with samples of uniform thickness. For homogeneous materials, the gas flow rate is generally inversely proportional to thickness.

In the world of materials science and plastics engineering, ensuring the integrity and performance of packaging materials is paramount. One of the critical properties of films used in food packaging, medical devices, and industrial applications is their ability to act as a barrier against gases. This is where the DIN 53380-1 standard comes in, providing a precise method for measuring gas transmission rates in plastic films. This standard remains a cornerstone of quality control in the plastics industry. By incorporating a volumetric approach to measuring how much gas passes through a film under controlled conditions, it helps manufacturers optimize materials for specific uses.

Gas permeability refers to the rate at which gas molecules diffuse through a material. For plastic films, low permeability is preferred to extend the shelf life of oxygen-sensitive products such as fresh produce or pharmaceuticals, while high permeability may be required for breathable membranes used in textiles or agriculture. Inadequate control of this property can lead to spoilage, contamination, or material failure.

The DIN 53380-1 standard addresses these needs by standardizing tests, ensuring compliance with international regulations, and facilitating trade. It is often cross-referenced with ISO 1399 and similar standards for rubber gas permeability, highlighting its interoperability in global testing laboratories. In an era dominated by eco-friendly plastics and advanced composites, accurate permeability data drives innovation, from biodegradable films to high-performance laminates.

The DIN 53380-1 standard is indispensable for industries based on polymer films:

• Food packaging: Measuring oxygen delivery to prevent oxidation in snacks or meats.
• Pharmaceuticals: Blister packaging ensures sterile environments by preventing moisture and gases from escaping.
• Electronics: Testing encapsulation materials for flexible displays against helium or nitrogen ingress.
• New technology: Evaluation of methane barriers in biogas storage films where volumetric methane permeability testing follows this standard.

Compliance with the DIN 53380-1 standard not only meets legal requirements (e.g., EU food contact materials) but also supports R&D for next-generation materials.

• The standard “DIN 53380-2 Part 2: Manometric method for testing plastic films” specifies a manometric technique for determining gas transmission velocity through thin plastic films. Unlike volumetric or carrier gas methods in other parts of the series, the manometric approach focuses on pressure differences, making it ideal for materials with medium to high permeability where pressure changes can be easily detected. The standard generally covers films with thicknesses between 20 µm and 3 mm, but adaptations for other ranges are possible upon request. It is compatible with international norms such as ISO 15105-1 for coulometric sensors, but emphasizes the simplicity of manometric testing for universal gas testing.

In the field of plastics testing, where sensitivity determines product reliability, the DIN 53380-2 standard emerges as a vital protocol for evaluating how gases interact with polymer materials. This standard builds upon previous iterations to provide a robust framework for manometric measurements. It complements the broader DIN 53380 series by offering a direct pressure-based approach to measuring gas permeability, making it indispensable for industries demanding highly efficient, reliable barrier assessments. This method is particularly valuable due to its applicability and simplicity to a wide range of gases, from oxygen to hydrogen, in films used in packaging, automotive components, and many other areas.

The DIN 53380-2 standard is widely used across various industries:

• Packaging: Evaluation of carbon dioxide barriers in beverage bottles or oxygen shields for perishable products.
• Automotive and energy: Evaluating hydrogen permeability in fuel cell membranes and enabling new devices to provide safe and standards-compliant testing.
• Medicine and electronics: Testing films for gas-tight seals in devices or displays.
• Sustainability: Measuring nitrogen or methane transfer in biodegradable films for agriculture.

This standard accelerates R&D by enabling rapid and versatile testing, as seen in thermoplastic polyurethanes where permeability data guide formulations for low-gas applications.

• The standard “DIN 53380-3 Part 3: Oxygen-specific carrier gas - Measurement method on plastic films and plastic molded parts” describes a method for determining the oxygen permeability (to pure oxygen or oxygen gas mixtures, e.g., to air) of plastic films, sheets, and hollow plastic bodies (e.g., packaging containers, plastic tubes), as defined in DIN 16922, thus enabling the evaluation of their suitability for packaging and engineering applications. This method can be used to determine permeability rates ranging from 0,05 cm³/(m²•d•bar) to 1000 cm³/(m²•d•bar) for films and sheets, and from approximately 0,0005 cm³/(d•bar) to 10 cm³/(d•bar) for hollow bodies. Here, d represents a unit of 24 hours.

In modern materials engineering, the precision of gas barrier performance is undeniable, and the DIN 53380-3 standard is considered the gold standard for measuring oxygen transmission rate in plastic films using the carrier gas method. This standard represents the most advanced and precise approach for oxygen-specific tests in the DIN 53380 series of standards. Unlike volumetric or manometric techniques, the carrier gas method uses a continuous flow system with a dedicated oxygen sensor and provides detection limits as low as 0,0005 cm3/(m2•d•bar), which is critical for high-barrier films used in food, pharmaceutical, and electronic packaging.

Oxygen is a key factor in oxidation, spoilage, and microbial growth in packaged products. Even trace amounts of permeability, such as 0,1 cm³/m²/day, can reduce the shelf life of sensitive products from months to weeks. In contrast, controlled oxygen supply is preferred in applications such as fresh produce packaging (modified atmosphere packaging) or wound dressings.

The DIN 53380-3 standard provides the following:

• Ultra-low detection limits for high-barrier materials (e.g., aluminum-coated PET).
• High repeatability (typically plus/minus 5 percent)
• Real-time monitoring with continuous gas flow.
• Compliance with (EC) no 1935/2004 and FDA 21 CFR regulations for food contact materials.

With the rise of flexible electronic devices, biodegradable barriers, and active packaging, accurate oxygen delivery rate data is essential for innovation and regulatory approval.

• The standard “DIN 53380-4 Part 4: Specific infrared absorption method for carbon dioxide testing of plastic films and plastic molds” describes an infrared absorption method for determining the gas transmission velocities of carbon dioxide, methane, nitrous oxide, and other infrared absorbing gases. This method, which guarantees international consistency, is compliant with the ISO 15105-3 standard.

In the complex world of polymer barrier testing, the DIN 53380-4 standard offers a specialized, high-sensitivity solution for measuring the transmission rates of carbon dioxide and other infrared-active gases through plastic films. This standard utilizes non-dispersive infrared spectroscopy to achieve selective, real-time detection with detection limits as low as 0,1 cm³/(m²•d•bar). Focusing on carbon dioxide-critical applications ranging from beverage packaging to modified atmosphere systems and sustainable biogas membranes, this standard complements oxygen-specific (DIN 53380-3), manometric (DIN 53380-2), and volumetric (DIN 53380-1) methods.

The DIN 53380-4 standard is widely used in the following areas:

• Beverage packaging: PET bottles must have a carbon dioxide loss rate of less than 10% over 3 months. This standard validates barrier coatings and recycled PET blends.
• Food packaging: Coffee, snacks, cheese, and other products require carbon dioxide-washed modified atmosphere packaging, which necessitates balanced entry/exit. This prevents the packaging from collapsing during transport.
• Biogas and renewable energy: Methane barriers in anaerobic digester liners. Methane filter (3,3 µm), compliant with DIN 53380-4, measures leakage risk.
• Pharmaceuticals: Vials and blister packs washed with carbon dioxide prevent oxidation without oxygen testing.

DIN 53380-4 is the precise standard for carbon dioxide and IR-active gas permeability in plastic films.

For many years, our organization, with its competent and experienced staff, has been understanding the needs of its clients, providing the advanced testing services they require, and assisting them in the establishment, implementation, and improvement of management systems. Within this framework, we also provide testing services to businesses in accordance with the "DIN 53380 Testing of Plastics - Determination of Gas Permeability" standard.