Leak Detectors

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Category: Dansensor

Leak Detectors for Seal Integrity

Seal Integrity is a vital aspect of quality control in Modified Atmosphere Packaging (MAP)

The importance of a leak detector for seal integrity

Sealing integrity is possibly the single most important element of quality control in MAP; if a package’s seal integrity is compromised, a leak will cause loss of the protective atmosphere and the shelf life of the food will be reduced, resulting in costly returns.

A package leak detector is therefore a vital part of MAP quality control. In recognition of this, Dansensor has developed state-of-the-art package leak detection equipment for testing the integrity of the seal.

Seal integrity can be compromised through a number of different routes. For example particles of the product being packaged may come between the tray and the seal. Another potential source of a breach in seal integrity is that the heating element that creates the thermal seal may be defective or misaligned, or there may be issues with the pressure, heat and duration of the sealing process. All these can result in seal integrity being compromised.

It is vital for quality control and quality assurance that leak detection equipment works as quickly and as accurately as possible. If seal integrity problems go undetected, issues are likely to arise with the product resulting in unwanted returns and potential damage to the relationship with a customer. Therefore, a reliable leak detector is vital to ensure seal integrity.

Package leak detection equipment for seal integrity

To ensure quality control and integrity of the seals, products coming off the packaging line must regularly undergo tests by package leak detector equipment.

The traditional way to undertake package leak detection to monitor seal integrity is to place the package in a water bath leak detector. The top of the vessel is then sealed and a vacuum applied to draw out the air. The reduced pressure in the bath causes the headspace gas within the package to expand producing a stream of bubbles in the water if integrity of the seal has been breached. These bubbles are visible to the package leak detection operator, who can then confirm the presence of a leak and a seal integrity problem.

This package leak detector system for seal integrity testing is a cumbersome, messy and time-consuming process, however.

Another seal integrity monitoring system, used for products such as cheese, is to keep the product in cold storage for a number of days to allow it to absorb all the carbon dioxide, which sucks the packaging material onto the surface to create a snug fit. If this tight fit is not seen, it suggests that a leak is present and the product must be repackaged. This, however, is a time-consuming and slow leak detector approach, and furthermore it needs a large amount of storage space.

Dansensor’s Package leak detection programme for seal integrity

MOCON Europe’s (Dansensor’s) leak detection systems offer both on-line and off-line leak detection of modified atmosphere packages and whole shipping crates for seal integrity assurance. Furthermore, Dansensor’s innovative leak detection equipment allows package leak detection non-destructively.

Off-line leak detector system for seal integrity

LeakPointer II is Dansensor’s off-line package leak detector system. The operator manually inserts the wrapped and sealed product into the testing chamber and lowers the lid. A pump evacuates the leak detector chamber, which is being constantly monitored for CO2.

If the seal integrity of the packaging has been compromised, the protective atmosphere will enter the chamber and the sensor in the package leak detector system will pick up the elevated level of CO2, a trace gas in many modified atmosphere packages. If the leak detection system does not indicate a leak – seal integrity is confirmed – the package remains intact and unspoilt.

On-line leak detector system for seal integrity

Automatic package leak detection is possible to integrate into the packaging line by using Dansensor’s innovative LeakMatic II on-line leak detector. The enlarged size of the LeakMatic II leak detector allows it to accommodate and test complete transport boxes for seal integrity.

Packages coming off the line can feed directly into the LeakMatic II leak detection control. As with the LeakPointer II leak detector the test chamber is evacuated and a sensor monitors changes in CO2 concentration to monitor the sealing integrity. It is possible to incorporate LeakMatic II at the end of the packaging line so that all units are tested.

An alternative approach is to divert random samples to a parallel conveyer which will feed these samples into the leak detector. For example, on a cheese production line one in every ten packages could be diverted into the LeakMatic II to provide reliable quality assurance for that particular production line.

If the leak detector is triggered, an alarm sounds and the relevant leaking packet is diverted along a reject line. The LeakMatic leak detector is also fast, and is able to test for sealing integrity in four to six shipping cartons each minute.

A cheese producer in the United Kingdom installed a Dansensor on-line leak detector and rapidly discovered that seal integrity had been compromised to a far greater extent than had previously been realised. With this leak detector the manufacturer was able to trace the fault to an upstream packaging problem and resolve the seal integrity issue (for more information on this leak detector success story, click on Case Study on the LeakMatic II page by clicking LeakMatic II on the side menu of this page).

Other Dansensor leak detector systems for ensuring seal integrity

MOCON Europe (Dansensor) has developed package leak detection equipment for seal strength and flexible and semi-rigid packages. The Lippke 4000 and 4500 are especially useful for packaging research and testing.

Testing seal integrity with a leak detector – summary:

  • Seal integrity is vital in modified atmosphere packaging
  • A leak detector is a key part of the seal integrity quality control process
  • Dansensor has developed a state-of-the-art leak detector programme for seal integrity test methods
  • The package leak detector methods are non-destructive
  • Dansensor’s package leak detector equipment can be used to test seal integrity off-line or on-line
  • Off-line seal integrity test methods are operated with a manual leak detector
  • On-line seal integrity test methods operate with an automatic leak detector
  • The on-line leak detector system is rapid, and can test up to six shipping cartons per minute for seal integrity
  • An efficient seal integrity monitoring system with a first-rate leak detector can identify potential problems with the packaging process before these problems become serious
  • Dansensor’s package leak detection equipment makes slow, old-fashioned seal integrity monitoring techniques such as a water bath leak detector redundant, and delivers much more efficient use of workers’ time
  • A Dansensor seal integrity monitoring system on your site will save you time in your leak detector programme and result in an efficient production line with the minimum of problems caused by seal integrity issues
  • An efficient leak detector saves time and money!

For further information on individual leak detector products to ensure seal integrity, click the relevant product in the menu bar on the left. To contact Dansensor about any of our leak detector products, click the ‘Contact’ button on the menu bar at the top of the page.

We can help ensure that you have a first-rate leak detector system on your production line so that you can be certain of your seal integrity!

MOCON Europe’s (Dansensor’s) leak detector range for seal integrity - LeakPointer II, LeakMatic II, Lippke 4000/4500

 

LeakMatic II Packaging Leak Tester

Fully automated non-destructive leak detector - seal integrity of all your modified atmosphere packages is ensured

Now with optical sensor

When the correct management focus is put on seal integrity the benefits can easily be seen in cost reductions. A well-established quality assurance will give reduced waste, reduced product returns, reduced labour and reduced loss of machine time. Hence giving an attractive return on investment time.

Dansensor has developed a compact in-line leak system, which gives the possibility of detecting leaky packages in complete shipping cartons. By using the CO2 already available in the MAP packages as trace gas, it is possible to test all packages shortly after they have left the packaging machine.

This test method is of course non-destructive and furthermore it is possible to test 4-6 shipping cartons per minute.

Benefits of the LeakMatic II packaging leak detector:

  • Fewer product returns

  • Fewer claims

  • Safer brand image

Features of the LeakMatic II packaging leak detector:

  • Optical sensor

  • No heating time

  • Data logging of measurement data

  • Fully automated non-destructive testing

  • Easy operation via touch screen

  • 3-year CO2 sensor warranty

 

LeakPointer II Seal Integrity Tester

Off-line leak detection of MAP products

Now with optical sensor

The table top LeakPointer II is the smallest of the Dansensor range of on- and off-line leak testers for modified atmosphere packages where CO2 is a part of the gas mix. 

The LeakPointer II will fast and easily discover seal integrity problems on all types of modified atmosphere packages with a minimum of 10% CO2 in the gas mix.

The consequences of leaking packages can be very expensive. In most cases avoiding a single product recall can easily justify the investment in a Dansensor leak detection unit.

Benefits of the LeakPointer II seal integrity tester:

  • Reduced costs from non-destructive testing 

  • Reduced risk of cross contamination (compared to traditional water bath)

  • Less risk of human error

  • Detects package leaks

Features of the LeakPointer II seal integrity tester:

  • Optical sensor

  • No heating time

  • Data logging of measurement data

  • Product programs can be selected via bar code

  • Fast testing cycle (< 30 sec.)

  • Easy operation via touch screen

  • 3-year CO2 sensor warranty

 

Leak Simulation Kit - Sets the Standard for Leak Size Measuring

Document well defined leak sizes

The Leak Simulation Kit is easy to use and helps simulate various predefined leak sizes in MAP packages. The high precision restricters represent different leak sizes. Using the Leak Simulation Kit will only require a minimum of instructions before you can implement it in your daily routines.

The Leak Simulation Kit is a quality assurance kit packed with everything needed to test and define acceptable leak levels in your packages. By using the Leak Simulation Kit you will get access to concrete workable data. You do not even need a new set-up because the Leak Simulation Kit works on your already existing set-up. This means that you are able to document very well defined leak sizes on your products and at the same time you will get concrete data to share with your customers. By testing your packages you will be provided with data that is accurate, realistic and measurable which makes you able to find the right settings for your packages.

Benefits of the Leak Simulation Kit for quality assurance

  • Create a common standard for leak sizes

  • Document well defined leak sizes

  • Find the right settings

  • Document the leak size for your customers

  • Calibrate the system to your packages

Features of the Leak Simulation Kit for quality assurance

  • The needle can be combined with four different restrictor sizes

  • Optional leak simulation size from 25 - 250 micron

  • The original Dansensor septum makes your measurement reliable

 

Lippke 4000/4500 for Leak and Seal Strength Testing

Leak and seal strength test systems for flexible and semi rigid packages

Package test system - burst testing of flexible packages

The package test systems Lippke 4000 and Lippke 4500 (PC-controlled) are designed for leakage and seal strength measurement on practically all types of flexible, semi rigid and rigid packages.

The systems provide exact, definable and reproducible test conditions.

The Lippke 4000 is a standalone test system with integrated user interface. It can be used in both production and laboratory environments.

Lippke 4500 is a computerised system which provides extended analysis facilities, storage and documentation of the test results.

The unit is compliant with (click standard below to visit ASTM for more information):

ASTM F1140 - Internal Pressurization Failure Resistance of Unrestrained Packages

ASTM F2054 - Burst Testing of Flexible Package Seals Using Internal Air Pressurization Within Restraining Plates

ASTM F2095 - Pressure Decay Leak Test for Flexible Packages With and Without Restraining Plates

ASTM F2096 - Detecting Gross Leaks in Packaging by Internal Pressurization