ASTM D3985 Oxygen Transmission Rate Test Through Plastic Film

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ASTM D3985 Oxygen Transmission Rate Tester | Coulometric Sensor OTR Test Machine | UnitedTest

UnitedTest manufactures precisionASTM D3985 compliant OTR testers equipped with professional coulometric sensors, designed to measure oxygen barrier performance for flexible plastic packaging and coated materials.

ASTM D3985 Standard Test Method for Oxygen Gas Transmission Rate Through Plastic Film and Sheeting Using a Coulometric Sensor is the industry-leading standard for steady-state oxygen permeability testing. It accurately determines the oxygen barrier properties of plastic film, sheeting, laminates, coextrusions, and plastic-coated paper or fabric materials.

This test method outputs three critical performance values: Oxygen Transmission Rate (OTR), Oxygen permeance (PO2), and Oxygen permeability coefficient (P'O2). The standard validated OTR testing range covers approximately 0.063 to 64.4 cm³/(m²·day). With equipment modifications, the tester also supports testing for poorer barrier materials with OTR values above 200 cm³/(m²·day).

Our ASTM D3985 coulometric OTR test machine delivers stable, repeatable steady-state oxygen transmission data for packaging quality control, material R&D, and industrial compliance verification.

Core Test Principle (Coulometric Sensor Mechanism)

The test relies on gas partial pressure difference driving diffusion and Faraday’s Law coulometric electrochemical detection:

A flat film specimen seals two isolated chambers under equal ambient atmospheric pressure, creating an oxygen concentration gradient. One chamber is fed pure oxygen test gas; the opposite chamber uses dry nitrogen as carrier purge gas.

Driven by oxygen partial pressure difference, oxygen molecules diffuse through the specimen into the nitrogen stream.

Nitrogen sweeps permeated oxygen to a coulometric sensor. Each oxygen molecule entering the sensor generates four electrons via electrochemical reaction. The sensor outputs a linear electrical current/voltage signal proportional to oxygen volume flux.

The sensor has intrinsic 95–98% efficiency and acts as an absolute reference standard without mandatory frequent calibration, though periodic verification with certified reference films is required.

After signal stabilizes to steady-state baseline, the voltage difference between zero-baseline (Eo) and oxygen-exposed steady state (Ee) is used to calculate OTR, permeance and permeability coefficient via standardized formulas.

Critical environment constraint: the test is strictly for dry conditions (relative humidity <1%); humid oxygen permeation testing follows separate ASTM F1927.

ASTM D3985 Oxygen Transmission Rate Test Through Plastic Film

Test Specimen Specifications

Cut flat, intact pieces matching the circular test area of diffusion cell; trim edges cleanly to avoid edge leakage.

Thickness measurement: minimum 5 evenly distributed measurement points over the full test area; record maximum, minimum and average thickness. Fragile thin films measure thickness after OTR testing to avoid caliper clamping damage altering barrier performance.

High-permeation film modification: mask most specimen surface with adhesive aluminum foil mask to reduce exposed test area and prevent coulometric sensor saturation.

Required Test Equipment of ASTM D3985 Oxygen Transmission Rate Test Through Plastic Film

Core Apparatus

Recommend UnitedTest Oxygen Transmission Rate (OTR) Tester;

Two-piece metal diffusion cell with circular test area defined by compressed O-ring (Buna or neoprene rubber O-rings for sealing). The effective test area A is measured from the O-ring imprint left on the specimen after testing.

Flat, scratch-free smooth raised rim on nitrogen carrier side for leak-proof specimen clamping; thermometer well built-in for real-time specimen temperature monitoring.

Pneumatic gas inlet/outlet fittings to prevent gas leakage during purging and testing.

Thermostatic temperature control system (heating/cooling) with precision ±0.5 °C, operable from 4 °C to 65 °C. Unsupported sagging/bulging film must not contact cell top/bottom inner walls.

Coulometric Detection & Data Recording System

Coulometric oxygen sensor (core detector, Faraday’s law response).

Load resistor (RL) to convert sensor current into measurable voltage signals.

Recording hardware options:

Multi-range potentiometric strip chart recorder: full-scale 50 mV, resolution ≥10 μV, input impedance ≥1 MΩ; minimum detectable signal 0.100 mV.

Computer-controlled automated instrument: integrated auto valve switching, gas flow regulation, temperature control, real-time signal capture and built-in calculation software, fully compliant with standard resolution and flow requirements.

Auxiliary Supplies & Instruments

Dry carrier gas: nitrogen blended with 0.5–3.0 vol% hydrogen, fully dehydrated; pure oxygen test gas.

Certified reference barrier film for periodic sensor/system calibration verification.

Metal mask (thin aluminum foil) for masking specimen area when testing high-permeation poor barrier films.

High-barrier metal foil/brass shim blank for leak validation checks.

Standard Test Parameters:

Carrier gas flow rate: Purge stage: 50–60 mL/min (3–4 min); steady test flow: 5–15 mL/min, continuous nitrogen flow to prevent air back-diffusion

Oxygen partial pressure difference: Normally 1 atm oxygen gradient (pure O₂ vs zero O₂ nitrogen carrier side)

Steady-state judgment: Sensor voltage signal maintains constant flat baseline with no upward/downward drift for extended period; thick high-barrier materials may require multi-hour overnight purging.

Full Standard Test Procedure of ASTM D3985 Oxygen Transmission Rate Test Through Plastic Film

Apparatus Preparation & Drying

If the instrument absorbed moisture in prior runs, remove water from gas humidifiers, bypass the coulometric sensor, and purge the whole system with dry nitrogen overnight; optional cell heating accelerates desorption.

Specimen Conditioning & Loading

Retrieve pre-conditioned dry specimen, mount it evenly between the two diffusion cell halves, clamp tightly to form full O-ring sealing with no wrinkles; record exact test temperature from cell thermometer well.

System Purge & Zero Baseline (Eo) Stabilization

Switch equipment to CARRIER PURGE mode, flush both cell chambers at 50–60 mL/min for 3–4 min, then reduce nitrogen flow to 5–15 mL/min and hold for 30 min. Monitor sensor signal until a stable flat zero baseline Eo is achieved (thick high-barrier films may require overnight purging). Record the zero voltage value.

Oxygen Gradient Introduction & Steady-State Capture (Ee)

Switch oxygen test gas into the upper cell chamber automatically (new instruments) or manually. Continuously track sensor voltage output until a permanent steady-state signal Ee forms with no upward/downward trend. Record stable Ee value and holding duration.

Post-Test Shutdown & Standby

Follow instrument manufacturer’s manual for long-term standby mode; stop oxygen supply, maintain low nitrogen purge flow to protect the sensor and prevent air ingress.

Data Calculation & Reporting

Compute OTR, permeance (optional), permeability coefficient (optional for homogeneous materials) using standard formulas; compile all mandatory data into a formal test report.

Industrial Application Fields

ASTM D3985 is the universal barrier testing standard for flat sheet/film materials, applied across these core industries:

Food Packaging: Flexible plastic pouches, EVOH barrier films, BOPP, PET, nylon laminates, aluminum-coated films, plastic-coated paper food wraps. OTR data predicts food oxidation, rancidity, discoloration and shelf life.

Pharmaceutical Packaging: Medical blister films, drug barrier sachets, sterile plastic sheeting—oxygen ingress degrades active pharmaceutical ingredients (APIs).

Electronics Packaging: Anti-oxidation barrier films for semiconductor components, lithium battery packaging laminates, moisture-oxygen sensitive electronic component wraps.

Agriculture & Horticulture: Greenhouse plastic sheeting, modified atmosphere crop packaging films.

Coating & Composite Materials: Plastic-coated woven fabrics, multi-layer coextruded films, extrusion-laminated barrier composites.

Related Test Standard:

ISO 15105-1	Plastics - Film and sheeting - Determination of gas-transmission rate - Part 1: Differential-pressure methods
ISO 15105-2	Part 2 – Equal-pressure method. adopting carrier gas equal-pressure principle instead of differential vacuum; complementary testing route for gas permeability measurement.
ASTM D3985	Standard Test Method for Oxygen Gas Transmission Rate Through Plastic Film and Sheeting Using a Coulometric Sensor
ASTM F1307	Standard Test Method for Oxygen Transmission Rate Through Dry Packages Using a Coulometric Sensor
ASTM F1927	Standard Test Method for Determination of Oxygen Gas Transmission Rate, Permeability and Permeance at Controlled Relative Humidity Through Barrier Materials Using a Coulometric Detector
JIS K 7126-2	Plastics -- Film and sheeting -- Determination of gas-transmission rate -- Part 2: Equal-pressure method
DIN 53380-3	Testing of plastics - Determination of gas transmission rate - Part 3: Oxygen-specific carrier gas method for testing of plastic films and plastics mouldings
ASTM F2622	Standard Test Method for Oxygen Gas Transmission Rate Through Plastic Film and Sheeting Using Various Sensors
GB/T 1038.2	Plastics—Film and sheeting—Determination of gas-transmission rate—Part 2:Equal-pressure methods
GB/T 19789	Packaging material—Test method for oxygen gas permeability characteristics of plastic film and sheeting—Coulometric sensor

Keywords: UnitedTest ASTM D3985 OTR tester, ASTM D3985 oxygen transmission rate tester, coulometric sensor oxygen barrier test machine, plastic film oxygen permeability tester, ASTM D3985 steady-state OTR testing for plastic sheeting, coulometric sensor PO2 and P'O2 permeability test, laminate and coextrusion oxygen transmission rate analyzer, plastic coated paper fabric oxygen barrier tester, 0.063–64.4 cm³/(m²·day) OTR test equipment for packaging films

Adopts advanced electrochemical coulometric detection method for accurate, time-efficient oxygen transmission rate analysis for medium and high barrier packaging materials. Conform with ISO 15105-2, ASTM D3985. Key testing indicators Oxygen Transmission Rate (OTR), oxygen volume passing through.

Gas Permeability Tester is a multi-functional lab instrument dedicated to gas barrier performance testing, gas transmission rate (GTR). Conform to ISO 15105-1, ISO 2556, ASTM D1434, Widely adopted as standard QC testing equipment for flexible packaging, plastic manufacturing and new energy sectors.

Q1. What exactly does ASTM D3985 measure?

A1: It measures the steady‑state oxygen gas transmission rate (OTR) through plastic film, sheeting, laminates, coextrusions, or plastic‑coated paper/fabric under dry conditions (RH < 1%). From one run you also get:

PO₂ = oxygen permeance

P′O₂ = oxygen permeability coefficient (homogeneous materials only).

Q2: Why is ASTM D3985 testing important for plastic barrier materials?

A2: Shelf life prediction: Oxygen oxidizes food, pharmaceuticals, cosmetics and electronic components; standardized OTR data quantifies oxygen ingress speed to calculate accurate product shelf life.

Material comparison benchmark: Uniform dry testing rules allow objective side-by-side evaluation of EVOH, PVDC, PET, PE, metallized films and coated substrates for packaging formulation design.

Commercial arbitration standard: The coulometric sensor has high inter-laboratory reproducibility; buyers and suppliers rely on D3985 results to resolve quality disputes and define acceptance criteria in contracts.

R&D & QC control: It validates barrier coating, metallization, and multi-layer laminate performance, supporting raw material incoming inspection and batch release quality checks.

Regulatory compliance: Food, medical and pharmaceutical regulators accept D3985 test data to verify oxygen protection for sensitive packaged goods.

Q3: What rules apply to test specimens for D3985?

A3: Specimens must be representative of the full film roll (sampled across width and length), free of wrinkles, pinholes, scratches or creases unless defects are inherent material features.

Trim clean flat pieces matching the cell’s circular test area to avoid edge leakage.

Measure thickness at minimum 5 evenly distributed points; fragile thin films measure thickness after OTR testing to prevent caliper damage altering barrier performance.

Pre-condition specimens in calcium chloride desiccator for at least 48 hours to remove residual moisture; new unknown materials need conditioning gradient tests to confirm stable OTR readings.

Q4: How to test poor barrier films with OTR >200 cc/(m²·day) without saturating the sensor?

A4: Two standardized solutions per D3985:

Mask most specimen surface with thin aluminum foil mask to reduce exposed test area and lower oxygen load into the sensor.

Use diluted oxygen-nitrogen mixed test gas to reduce the oxygen partial pressure difference across the film, then recalculate equivalent OTR for 1 atm gradient using permeance data.

Q5: What humidity environment does ASTM D3985 specify? What standard covers humid OTR testing?

A5: D3985 strictly requires dry test conditions with relative humidity <1% only. It cannot simulate real-world humid packaging environments (e.g., high-moisture food). For controlled RH oxygen permeation testing, use ASTM F1927, which shares the same coulometric detection principle but supports adjustable humidity levels.

Q6: What is the difference between ASTM D3985 and ASTM D1434?

A6: D3985 = coulometric sensor method (electrochemical detection, equal-pressure dry test, widely used as referee method).

D1434 = manometric pressure-change method, measures gas pressure drop instead of electrical signals.

NIST-verified reference material data shows strong correlation between the two methods, but D3985 offers faster testing and higher sensitivity for low-OTR high-barrier films.

Q7: What is the measurable OTR range of D3985 without masking?

A7: The standard validated linear measurement range is 0.063 cc/(m²·day) to 64.4 cc/(m²·day). Films above 200 cc/(m²·day) are defined as poor barriers and require masking or diluted test gas to avoid detector saturation

Q8: How long does a full D3985 test take to reach steady state?

A8: Depends on barrier performance:

High-barrier films (EVOH, foil laminates): May require several hours or overnight purging to stabilize zero baseline Eo.

Medium/low barrier films (PET, PP): Typically stabilize within 30–120 minutes after oxygen gas introduction.

Q9: Why must nitrogen carrier gas keep flowing continuously even when the instrument is on standby?

A9: Continuous low nitrogen purge prevents atmospheric air back-diffusion into the system. Ambient oxygen leaking into the sensor will deplete the electrolyte, shorten sensor service life, and introduce false high OTR baseline readings in subsequent tests.

Steady state is confirmed when sensor voltage output shows no upward/downward drift for an extended period.

Q10: What causes unstable zero baseline (Eo) drift during purging?

A10: Three primary root causes:

System gas line or diffusion cell leakage allowing ambient oxygen ingress.

Residual moisture or volatile outgassing from previous test specimens contaminating the carrier gas stream.

Degraded coulometric sensor electrolyte reducing signal stability.

Mitigation: Purge the full system overnight with dry nitrogen, test blank metal foil to check for leaks, and replace aged sensors when drift persists.

Q11: Can D3985 test finished 3D packages like bottles or sealed pouches?

A11: No. D3985 only applies to flat film and sheet specimens. For complete sealed 3D dry packages, use ASTM F1307, another coulometric OTR standard designed for whole-container testing.

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