diff --git a/.gitea/workflows/pack.yaml b/.gitea/workflows/pack.yaml
index c27aa9ee..1437c6f9 100644
--- a/.gitea/workflows/pack.yaml
+++ b/.gitea/workflows/pack.yaml
@@ -215,6 +215,16 @@ jobs:
           rm -rf "$WORK/out/cms/.git" "$WORK/out/cms/node_modules" 2>/dev/null || true
           cp -r "$WORK/src/catalogus" "$WORK/out/catalogus" 2>/dev/null || true
           rm -rf "$WORK/out/catalogus/.git" 2>/dev/null || true
+          # Diagnostics: show each component size before packing.
+          for d in cms catalogus nitro render emulator; do
+            echo "out/$d: $(du -sh "$WORK/out/$d" 2>/dev/null | cut -f1) ($(find "$WORK/out/$d" -type f 2>/dev/null | wc -l) files)"
+          done
+          # Hard guard: every component must be present and non-empty.
+          for d in catalogus nitro render emulator; do
+            if [ ! -d "$WORK/out/$d" ] || [ -z "$(find "$WORK/out/$d" -type f 2>/dev/null | head -1)" ]; then
+              echo "ERROR: component '$d' is missing or empty in the pack"; exit 1
+            fi
+          done
           cp "$WORK/components.txt" "$WORK/out/COMPONENTS.txt"
           echo "Built at $(date -u)" > "$WORK/out/BUILD_INFO.txt"
           cat "$WORK/components.txt" >> "$WORK/out/BUILD_INFO.txt"