black caps with liners on assembly line
Hidden Role of Liners in Packaging Safety
Written by
Ned Burnett
Julien Guidici
Published on
06 October 2025
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3 minutes
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Ned Burnett
Ned Burnett
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Julien Guidici
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What a Microplastics Study Reveals About the Hidden Role of Liners in Packaging Safety

A recent study from France has raised new questions about packaging safety, particularly related to a component that rarely gets the spotlight: the bottle cap. Researchers from the French National Agency for Food, Environmental, and Occupational Health and Safety (ANSES), analyzed a wide range of popular beverages and found that glass bottles, often viewed as the premium or "cleaner" packaging choice, consistently had the highest levels of microplastic contamination.  

In some cases, beverages in glass bottles contained over three times the amount of microplastics found in the same beverages packaged in plastic bottles or aluminum cans. Beer, lemonades, colas, and cold teas all showed significantly elevated microplastic levels when packaged in glass. Even plain bottled water was affected. But the glass itself wasn’t the issue. 

The problem came from the bottle’s cap.

Specifically, from the polyester-based paint used on the interior and exterior surfaces of metal caps. These coatings are prone to abrasion and flaking during production, transport, and storage. The microplastic particles they release, often invisible to the eye, end up in the liquid as the bottle is opened and poured. When researchers cleaned the caps before bottling, contamination dropped significantly. When left untreated, it spiked.

This finding underscores the hidden risks in packaging safety and highlights the critical role of liner systems in preventing contamination, especially in sensitive applications like medical diagnostics, pharmaceuticals, and specialty chemicals. 

Why Closure Design is Critical in Medical & Pharmaceutical Packaging

Saint-Gobain Medical does not manufacture closures for soda or beer bottles. But we do support customers in medical diagnostics, pharmaceuticals, laboratory sampling, and specialty chemical applications, where the performance of a closure system is directly tied to the reliability and purity of the product inside.

The ANSES study highlights a broader point that applies across all sectors. It is not enough to trust the materials that make up the container itself. The entire packaging system, including the cap, liner, seal, and any coatings or adhesives, needs to be evaluated. A small design decision, such as the choice of a decorative coating or backing adhesive, can introduce trace-level contaminants that build up or react with the product.

For sensitive applications, especially where sterility, purity, or analytical accuracy is required, the liner system serves as a critical barrier. It controls what enters the container and prevents unwanted material from migrating into the product. 

What Makes a Closure System Robust

black caps with white liners on conveyor belt
Saint-Gobain Specialty Closure Systems

Designing a liner system that performs reliably under these conditions means looking beyond just basic compatibility. Factors such as particle shedding, solvent resistance, sealing force, and mechanical wear all need to be taken into consideration.

At Saint-Gobain Medical, our liner systems are often built using multi-layer structures that combine:

  • Inert contact materials to reduce extractables
  • Functional barriers for oxygen, moisture, or solvent protection
  • Compression layers that support a consistent seal under variable torque
  • Reliable backing structures that anchor the liner in the cap

Each element is engineered to support the full use case. Whether the packaging is intended to withstand long-term storage, repeated opening and closing, or exposure to temperature swings, the liner plays a central role in ensuring that what's inside stays stable and clean.

Designing for Cleanliness from the Start

The most important takeaway from the microplastics study is that contamination risks often originate in places that are easy to overlook. In this case, a common packaging component, the painted bottle cap, was introducing particles into products that were otherwise clean. The ANSES microplastics study is a powerful reminder that packaging safety depends on more than just the container: it hinges on the integrity of the entire closure system.

This is the kind of systems-level thinking that drives closure design in regulated markets. It is not just about keeping the container sealed. It is about making sure every part of the closure works in harmony with the product it is meant to protect.

If purity and performance matter, the closure cannot be treated as an afterthought. It needs to be designed from the start, with the liner doing much of the heavy lifting.