Design issues may cause pressure-activated PRDs to actuate prematurely. The resultant thrust can lead to the cylinder getting propelled dangerously, causing safety issues and product loss.

Internal plug capsule design uses a washer for secure sealing, reducing torsional stress on the burst disc and preventing the PRD from loosening, damage or premature failure. Cross-flow design diverts the escaping gas in a plane parallel to the cylinder's longitudinal axis to balance the thrust forces and prevents cylinder tipping.