The food processing and packaging industries worldwide are constantly investigating and researching options to introduce cost effective solutions for plant and equipment. The introduction of new technology to create productivity gains is a very attractive proposition to company stakeholders, especially if the Internal Rate of Return (IRR) is attractive. Technology developed by authors using non-destructive testing using digital imaging and sensing combined with a differential vacuum technique is to assess seal integrity of food packages on a high-speed production line. This paper analyses current availability and costs of available machinery versus the cost of the new proposed technology. Total costs of the plant and equipment, including manufacture, operations, quality, maintenance and servicing costs are discussed. An increase in quality using this technology helps the food product company to market its brand as sound product with good ethics behind the brand. It also reduces consumer complaints, thus being a positive aspect from a marketing perspective. A cost effective solution has a different meaning to the various departments that make up a food processing or packaging business. Costs saving benefits to various departments are discussed, for or batch product unit or stock keeping unit (SKU).