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What goes wrong

It went flat

Updated

On this page5

The mirror failure, less dangerous and more common as a complaint.

Gas leaves

A carbonated drink that has lost its gas tastes flat, sweeter and duller, because carbonation contributes perceived acidity and sharpness as well as texture.

Customers describe it as the product tasting wrong rather than as flat, which makes it harder to diagnose from a complaint.

Where it goes

Through the closure. The commonest route: a liner not suited to the closure or the product, or torque outside tolerance.

Through the container. PET is permeable to carbon dioxide, and a thin-walled PET bottle loses noticeable gas over months. This is why carbonated PET products have a shorter stated life than the same drink in glass.

At filling, if the product was filled warm or turbulently, so it never contained what the specification says.

Into the headspace, which is an equilibrium: a large headspace holds more gas out of solution, so an under-filled bottle tastes flatter.

Diagnosing which

Measure carbonation at filling. If it was low then, it is a process problem rather than a package one.

If it was right at filling and low later, hold retained bottles and measure over time: a steady decline points at permeation, and a sudden loss at a seal.

Check torque on the retained bottles. A closure that has loosened tells you immediately.

Fixing it

Glass or a barrier-coated container for a long shelf life.

A closure and liner specified for carbonated product, applied at a controlled torque.

Fill cold, fill gently, and fill to the target level.

And set the shelf life to what the package actually holds rather than to what the liquid would tolerate.

References

No published source. This page is written from practice rather than from published guidance. No extension service or agency publishes on this question for beverages, so nothing here is cited, and it should be weighed as experience and not as a standard.
Written from the federal regulation and agency guidance named on each page, not from a laboratory. Whether a particular product meets a pathogen reduction requirement, and what its alcohol content actually is, are measurements about your product, and this is not those measurements.