Headspace Gas Analyzers

The importance of headspace gas analysis for quality control in Modified Atmosphere Packaging (MAP)

In packaging terms, the headspace refers to the internal volume of a package that is not occupied by the product. The atmosphere in this space is termed the headspace gas. Headspace analysis is the measurement of this headspace gas. Headspace gas analysis is a key part of the quality control process for the food, beverage and pharmaceutical industries for products that have been packaged in a modified atmosphere.

Headspace analysis ensures that the residual oxygen within the headspace gas does not exceed certain defined limits: excessive oxygen within the headspace can result in the growth and proliferation of microorganisms such as bacteria or moulds, which causes spoilage and results in a lower shelf-life of the product. Headspace analysis usually focuses primarily on oxygen measurements, but in many cases CO2 measurement is also important.

How does headspace analysis work?

To carry out headspace analysis, packages are removed from the production line for testing. A thin needle is inserted into the package and a pump draws a small sample of precise volume of headspace gas into the analyzer equipment. The headspace gas comes into contact with a sensor that can measure the concentration of residual oxygen or carbon dioxide in the headspace gas sample.

The headspace analysis equipment – the headspace gas analyzer – provides a reading of the concentration of the gas that is being measured. In cases where products are coming off a line very rapidly, the speed at which headspace analysis can be carried out can be an important factor. In these situations it is much more efficient for an operator to be able to carry out a headspace gas analysis on a sample in, say, five seconds than in 30.

For certain products in transparent foil containers, it may be possible to use an optical oxygen detector to carry out headspace analysis in a non-invasive way.

Dansensor’s testing equipment for headspace analysis to ensure MAP product quality

MOCON Europe (Dansensor) offers a range of different solutions for headspace analysis of MAP products across all relevant industries and sectors:

- CheckPoint 3

- CheckMate 3

- OpTech

CheckPoint 3 is our brand new portable headspace analyzer with the newest sensor technology and a low cost of ownership.

Furthermore the CheckPoint 3 offers a good deal of benefits and features, among others a long-lasting sensor, data collection/transfer via WiFi and statistic data analysis.

CheckMate 3 is ideal for larger production facilities and customers with a demand for high accuracy quality control. With CheckMate 3 it is possible to set up a complete workflow for headspace analysis of packages, bottles and pharmaceutical products. It has an easy-to-use barcode option that enables the collection of vital data such as batch number, packaging line, package type and the operator’s name, and is available with a high accurracy Zirconia sensor for oxygen measurements down to ppm range.

OpTech-O2 Platinum gives the operator the ability to measure oxygen in a non-invasive manner through a transparent foil.

Headspace analysis in MAP packaging with high carbon dioxide concentrations

As well as residual oxygen measurements for headspace gas analysis, CheckPoint, CheckPoint II and CheckMate 3 can also have the option to test for both O2 and CO2, to improve quality control by ensuring that the headspace gas mixture is correct.

In summary

In seeking to advance sensing technology, MOCON Europe (Dansensor) has developed equipment for MAP headspace gas analysis for every application:

• accurate residual O2 headspace gas analysis
• O2 headspace gas analysis in the presence of high CO2
• robust, portable headspace gas analyzers
• dedicated O2/CO2 headspace gas analyzers
• MAP audit applications
• MAP quality control

For further information about any of these headspace analysis products, please visit the relevant web page on the menu on the left, or contact MOCON Europe (Dansensor): details provided on the Contacts page on the menu bar above.

CheckMate 3 Headspace Gas Analyzer

A flexible, fast and accurate benchtop gas analyzer for headspace analysis for quality control of Modified Atmosphere Packaging

If one thing is important in branding it’s “repeatability”—being able to deliver the same consumer experience, every single time. How to make sure your product lives up to buyer expectations? Test, test, test – preferably with a reliable headspace analysis instrument, such as CheckMate 3.

CheckMate 3 is a benchtop headspace analysis instrument that allows headspace oxygen analysis or combined oxygen/carbon dioxide analysis of gas-flushed packages to be carried out fast and cost-effectively – a necessity for high-volume brand-name manufacturing. Operators can tell at a glance if the headspace gas composition is within the required levels. It also provides the traceability you need: essential data about each and every package can be stored in the unit itself or transferred either to the CheckMate 3 software or third-party software. And because different products have different testing requirements, the gas analyzer can be adapted to virtually any headspace analysis quality control system, making brand consistency easier than ever to maintain.

Benefits of CheckMate 3 for headspace analysis 

• Saves labour time and paperwork due to automatic data logging

• Easy transfer of quality-control data to the CheckMate PC software and third-party software

• Reliable quality control of gas flushed products

• Easy operation – minimum of training required 

Headspace analysis features of CheckMate 3 

• Large easy to read 5” colour display with touch function

• Available for either headspace oxygen analysis (O2) or combined headspace oxygen/carbon dioxide (O2/CO2) measurement

• Very small headspace analysis sample volume requirement (from 3 ml)

• Data transfer via Ethernet, USB and RS232

• Flexible configuration of test scheme, e.g. logging of operator name, batch number, product line, etc.

• USB connection for external keyboard and bar code scanner

• Optional built-in printer

CheckPoint 3 - Portable Gas Analyzer for Quality Control of Modified Atmosphere Packages (MAP)

New revolutionary sensor technology

The new CheckPoint 3 is the most advanced portable gas analyzer on the market, enabling you to quickly and easily check for O2 and CO2 levels in Modified Atmosphere Packages (MAP) of any shape and size.

With the new long-lasting sensor, the CheckPoint 3 delivers the highest level of accuracy on portable analyzers, making the packaging process more reliable.

WiFi connectivity ensures a new unique user experience. With the web interface fast, easy and reliable data management is guaranteed. The high quality color screen combined with intuitive interface give a clear process overview and extremely easy testing traceability and transparency.

CheckPoint 3 is perfect for productions looking for portability, best accuracy and just as important, a low cost of ownership.

Benefits of the CheckPoint 3 portable gas analyzer

• No PC software required

• Easy to use

• Improves MAP quality control

• Better process efficiency

• Greater business transparency

• Secures your brand’s reputation

• Highest level of portable analyzer

• Low cost of ownership

• No daily 20.9% calibration

Features of the CheckPoint 3 portable gas analyzer

• NEW Ceramic solid state O2 sensor

• O2 or combined O2/CO2 measurements

• Gas flow alarm

• Data collection/transfer via WiFi

• Faster processing

• Easy-to-read 3.5" color touchscreen

• Uses standard, low-cost needles

• Optional stainless steel needles

• Data package,1 million data logs

• 3 years warranty on sensor

• Protection cover

• Multiple languages

• Graphic statistics

PC Software for the CheckMate Analyzers

The easy to use “CheckMate PC software” enables the control of several CheckMate units in a production environment.

The PC software makes it easy to create and manage users and products, to set up product measurement details and to monitor general device settings.

During the day all measurement data can continuously be transferred from the analyzer to the application database  via the local area network (LAN). At the end of the day all collected data can be reviewed in the software or exported for further analysis. This enables quality control managers to easily evaluate data from even very large production facilities working with modified atmosphere packaging.

Download evaluation copy MAP gas analyzer pc software

The CheckMate PC software with support for both CheckMate II and CheckMate 3 is available for a free 30-day evaluation.

Please note that the software only can connect to CheckMate II analyzers with a firmware version 2.14 or later. Without a firmware upgrade you will still be able to evaluate the software features, but not download actual measuring data from your CheckMate II.

Download PC software CheckMate II & CheckMate 3 to the right.

Upgrade kits are avalible from your local MOCON Europe (Dansensor) distributor. In order to upgrade your existing CheckMate II you should refer to the following part number: 290190  - Upgrade Kit, CheckMate II PC Software

If you are ordering the PC software with a new CheckMate 3 you should refer to the following part number: 290142 - Option, CheckMate PC software.

Can Piercer

The Dansensor Can Piercer is an option for our CheckMate 3 and CheckPoint 3 headspace analysers. The Can Piercer can, among others, be used for measuring headspace in the following packaging types: 

• Milk powder cans
• Soft drink cans
• Wine bottles
• Ready to drink containers
• PET bottles

The CheckMate 3 only requires a very small amount of headspace to ensure a reliable result. The CheckMate 3 with can piercer is therefore a perfect tool for measuring in bottles etc. with a small headspace.

OpTech Optical Oxygen Sensor

Multipurpose optical oxygen measurement - versatile and innovative

The OpTech® - O₂ Model P is a simple yet effective tool for any laboratory with the need to measure oxygen inside a closed package or container. The OpTech gives the user the ability to measure the oxygen in a non-invasive manner through a transparent foil – making it perfect for shelf life determination of oxygen sensitive products. 

Additional accessories like the OpTech needle and the ImPULSETM sensor enable the OpTech to measure oxygen in applications with limited headspace and also to measure oxygen through opaque packaging material.

The OpTech measures oxygen using an optical principle, which means that it does not extract any gas from the sample and thus makes it ideal for long-term testing of the same package.

Benefits of the OpTech optical oxygen sensor

• No gas extraction

• Fast reading of O2

• Shelf life testing

• Headspace measuring

Features of the OpTech optical oxygen sensor

• Non-invasive measurement

• Light weight

• PC software included

• Invasive needle