Online Gas Analyzers

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Category: Dansensor

 Online Gas Analyzers for Gas Packaging Machines

On-line gas analyzers: moving from quality control to quality assurance for MAP

In MAP, quality assurance is key. Producers must be confident that their modified atmosphere packaging equipment is working correctly and that their gas mixing system is delivering the correct protective atmosphere to ensure the prolonged shelf-life of food or other products such as beverages or pharmaceuticals. Control of the gas flushing process is therefore vital.

In the past, to ensure the correct gas mixture was present in a MAP product, the operator would need to select samples off the packaging line at random and carry out a headspace analysis of the gas within the package. This however is a destructive test, meaning that samples would need to be repackaged; and it is time-consuming and labour-intensive. Also, if headspace gas measurements show that the mixture is not as it should be, then further packages need to be tested downstream as these too may not have the correct mixture.

While this procedure remains important for quality control purposes, Dansensor’s range of gas analyzers allow constant monitoring of the gas mixture on the packaging line. Use of on-line gas analyzers permits a move away from time-consuming quality control towards constant quality assurance for MAP through close control of the gas flushing process.

Previously, operators would simply have to trust that their gas blenders were providing the correct mixture, or that the pre-mixed gases provided by the supplier were of the correct quality and composition. And often, to reduce the risk of unwanted oxygen entering the package, operators would use excess modified atmosphere gas just to be on the safe side. This is not only potentially wasteful – more gas equals greater cost – it can also make for a less-than-ideal working environment for the operators.

Now, however, 100 per cent process control of modified atmosphere products is possible through on-line gas analyzers. Manufacturers are now able to ensure that the shelf-life of food meets specifications, and at the same time reduce the risk of costly and time-consuming repackaging of products. High Precision constant monitoring of the incoming gas with gas analyzers also means that it is not necessary to use excess packaging gas – which can result in significant cost savings on vertical and horizontal flow packaging machines where Dansensor’s gas analyzers have optional flow control.

Dansensor’s on-line gas analyzers deliver the perfect solution

MOCON Europe (Dansensor) offers a range of gas analyzers for on-line process control of MAP products and control of the gas flushing process.

Different gas analyzers are available, tailored to the particular needs. The analyzer concept is essentially the same for all cases. A stream of the packaging gas is continuously withdrawn from the MAP line and is passed through a filter and into the gas analyzer, which constantly measures oxygen or oxygen/CO2 levels in the mixture. The highly accurate oxygen sensors in the gas analyzers are zirconium based.

MOCON Europe (Dansensor) provides a range of on-line gas analyzers for control of the gas flushing process depending on the type of modified atmosphere packaging line. For horizontal or vertical flow wrap systems, the packaging gas is withdrawn through a hose attached to a pump. Where the packaging gas is introduced via vacuum, as for thermoforming and tray sealing machines, the gas sampling system is appropriately modified so that MAP gas is also drawn into the gas analyzer at the same time as it is introduced to the packaging itself. We also have an on-line analyzer for situations where gas mixture is under pressure. By using these gas analyzers, quality assurance for MAP is therefore guaranteed for all circumstances and all types of MAP line.

The gas analyzer is programmed depending on the product, with threshold levels of the gases pre-defined by the operator. If the concentration of oxygen within the modified protective atmosphere rises above the threshold level, for example, the gas analyzer sounds an alarm, alerting the operator. An alternative option is to have the gas analyzer fitted with two alarms. One ‘warning’ will alert the operator that the threshold level is being approached. This gives the operator the ability to make any necessary adjustments to the gas mixing system to bring levels into the desirable range without having to stop the MAP packaging line: a useful time- and cost-saving option.

As an additional feature, it is possible to couple Dansensor’s MAP Check 3 family of on-line gas analyzers with Dansensor’s Map Mix Provectus gas blender to provide a feedback control system: the gas analyzer will ‘tell’ the mixer that the desired oxygen level is not correct, and the gas flow from the Provectus gas mixer will  automatically be adjusted.

On-line gas analyzers – summary:

Dansensor’s on-line gas analyzers for packaging machines provide

  • quality assurance for MAP
  • control of the gas flushing process
  • time savings as the operator moves away from random quality control headspace measurement to quality assurance through constant on-line measurement of the gas mixture
  • cost savings through using much more precise gas mixtures and avoiding excess use of gas
  • user-friendly touch-screen interface on MAP Check 3 range and excellent data-logging for traceability

For further information on MOCON Europe's (Dansensor’s) range of state-of-the-art on-line gas analyzers for quality assurance for MAP and control of the gas flushing process, click the relevant product in the menu bar on the left. To contact Dansensor about any of our gas analyzers, click the ‘Contact’ button on the menu bar at the top of the page.

We can help ensure that you have a first-rate gas analyzer on your production line!

 

MAP Check 3 for Vertical or Horizontal Flow Packaging Machines

A smarter way to control your MAP process

MAP is the future. But companies using more gas than necessary to produce MAP products run the risk of becoming history.

That’s why we’ve designed this gas analyser to be so precise. With the MAP Check 3, the gas target you set is the gas dosage you get. It eliminates the all-too-common problem of well-intentioned operators using too much gas, without realising its effect on production costs.

The only thing the MAP Check 3 increases is your flexibility. It lets you combine monitoring of gas content on a vertical or horizontal flow packaging machine with real-time control of package flushing via an advanced GasSave function. For most manufacturers, this translates into a 20-50% decrease in gas consumption!

It also improves reliability and efficiency. Unlike random, off-line quality control, on-line quality assurance with the MAP Check 3 means that every package is tested — far more quickly and efficiently than with manual testing. And if there’s a problem, production stops automatically, helping to avoid recalls or the need to repack entire batches. Read how a meat producer of processed food is saving gas.

Benefits of the MAP Check 3 gas analyzer for modified atmosphere packaging flow wrappers

  • Enables major gas savings with optional GasSave function or when paired with MAP Mix Provectus gas mixer

  • Logs and displays actual gas consumption for easy traceability with GasSave function

  • Reduces labour and waste costs compared to manual testing

  • Avoids recalls/repacking by stopping packaging machine if machine exceeds preset limits

  • Reduces work area CO2 levels to protect employees

Features of the MAP Check 3 gas analyzer for modified atmosphere packaging flow wrappers

  • NEW: 5” colour touch screen

  • NEW: Improved data logging capabilities with USB, Ethernet, TCP Modbus

  • NEW: Ability to control MAP Mix Provectus gas mixer

  • NEW: Delivered with PC software

  • NEW OPTIONS: IP45 protection kit, 3-channel multiplexer

  • Optional built-in GasSave flow controller

 

MAP Check 3 Pressure Oxygen Gas Analyzer

A flexible way to control your gas

Are you always getting the right blend of gas? Did you know that your bottom line becomes as invisible as the gas you are using if you supply the wrong gas mix to you processes?

Dansensor has designed the MAP Check 3 Pressure gas analyzer to ensure that you are always getting the right blend of gas.

The MAP Check 3 Pressure is a simple and efficient gas analyzer that measures pressurised gases directly from a gas mixer, buffer tank or any other pressurised source.

It is able to measure both oxygen and carbon dioxide and it can check your gas for oxygen impurities. Furthermore it measures the balance between the gases.

Last but not least the MAP Check 3 Pressure gas analyzer can be coupled to the MAP Mix Provectus gas mixer. MAP Check 3 works seamlessly with the MAP Mix Provectus to constantly monitor the composition of the gas mixture and prevents incorrect gas mixtures. This sophisticated feedback control ensures that the correct mixture is delivered at all times for ultimate efficiency, consistency and quality insurance, thereby reducing waste and increasing cost savings.

Benefits of the MAP Check 3 Pressure oxygen gas analyzer

  • Ensures that the right gas mix is supplied to your process

  • Logs and displays actual gas mix

  • Works with inlet pressures from 2-10 bar (30-145 psi)

  • Can stop your process before the wrong gas mix is supplied

Featires of the MAP Check 3 Pressure zirconia oxygen analyzer

  • 5” colour touch screen

  • Improved data logging capabilities with USB, Ethernet, TCP Modbus

  • Ability to remote control the MAP Mix Provectus gas mixer

 

MAP Check 3 Vacuum On-line Gas Analyzer for Quality Assurance of MAP

A win-win for thermoforming and tray sealing lines

Customers want higher quality assurance levels… Management wants higher production rates… Here’s pleasing news for both.

The MAP Check 3 Vacuum gas analyser lets you step up — from random quality control checks to on-line quality assurance — and speed up production as well. By measuring gas composition on a continuous basis, it ensures that each and every package is flushed to spec — a big win for your customers. And because testing is carried out automatically, process lines can be run at high speeds without compromising quality — management will thank you too.

Automatic testing with the MAP Check 3 Vacuum isn’t just faster and more reliable than manual testing — it’s also more efficient. If there’s a problem with gas content, the system notifies the operator immediately — there’s no waste of time. And if preset limits are exceeded, the analyser simply stops the process — so there’s no waste of products or packaging either.

 Benefits of the MAP Check 3 Vacuum analyzer for MAP tray sealers

  • Stops packaging machine if preset gas limits are exceeded

  • Measures every packaging cycle

  • Continuous process monitoring of gas content

  • Reduces labour and waste costs compared to manual testing

  • Avoids recalls/repacking by stopping packaging machine if machine exceeds preset limits

Features of MAP Check 3 analyzer for MAP tray sealers

  • Oxygen or combined oxygen and carbon dioxide measurement

  • Alarms for low or high gas concentrations

  • Improved data logging capabilities with USB and Ethernet

  • Ability to control the MAP Mix Provectus gas mixer

  • Delivered with PC software for LAN based data collection

  • Optional measurement of buffer tank gas composition and pressure. User configurable alarms

 

ISM-3 Oxygen Process Analyzer

Industrial sensor module for O2 monitoring - Process analyzer with low maintenance demand

          

The Industrial Sensor Module - ISM-3I - is an oxygen (O2) monitor. It measures oxygen in inert gases and CO2 and targets applications like the various types of nitrogen generators.

The O2 monitor ISM-3I is a digitally controlled analyzer, featuring user programmable gas alarms and complete self-diagnostics with system alarms. The oxygen monitor is an extremely versatile analyzer with very low maintenance requirements and high reliability.

The Dansensor O2 monitor ISM-3I features separate sensor and display boxes with user interface for easy panel mounting. This allows for mounting of the small display unit where convenient and the sensor unit can be placed out of the way.

Benefits of the ISM-3 oxygen process analyzer:

  • High reliability and accuracy - better than ± 1% of reading

  • Low maintenance demand

  • Large measuring range: 1 ppm - 100%, with automatic range selection

  • Self diagnostics - monitoring of vital parameters with alarm output

 Features of the ISM-3 oxygen process analyzer:

  • 2 oxygen concentration alarms

  • Sample gas supply by gas pressure or internal pump (specific instrument versions)

  • Different set-up options for adaptation to the analyzer application

  • 0/4 - 20 mA as standard (optional: 0-10V if specified with the order)