Package seal testing enables manufacturers to ensure that food packaging offers the necessary product protection. In manufacturing, seal integrity tests are frequently used to evaluate seal strength and confirm no package leak. Ensuring no leaks in packages will bring cost optimization and reduce production waste.
The Sealtick TSE6086b leak tester has been widely used to verify the seal integrity of packages in the food manufacturing industry. Suppose we compare this to the conventional underwater leak tester. In that case, this non-destructive leak testing system can find package leaks without compressing and damaging the package, allowing it to be reused or returned to the packing line. Since operators can return the products to the production line, it generates no manufacturing waste, provided that the package passes the test. It also offers significant cost savings, primarily when used for testing packaging that contains high-value commodities such as milk powder.
In the packaging industry, verifying the seal integrity of packaging containing perishable goods or goods vulnerable to environmental contamination is common. A leak testing standard is developed to ensure that contaminants, such as air, oxygen, moisture, germs, and soil, do not enter the package. These contaminants will damage the products and shorten their shelf life if they come in contact with them.
For instance, moisture is a reaction catalyst to the decomposition reaction of organic materials. It accelerates product decomposition and encourages the development of mold and aerobic bacteria. It is the reason behind using modified gases like carbon dioxide and nitrogen to fill packages to preserve the content and increase their shelf life.
The traditional method of visual leak testing such as underwater leak tester, is considered ineffective and undesirable. There is always a possibility that a micro leak might go undetected as the test results heavily rely on the operator. If there is an error in judgment, there is a chance that a large batch of compromised packages may be undetected, which will bring considerable losses if they make their way to the market. While most customers examine the packaging’s outward appearance to inspect for damage, they might not notice the small leaks. They may buy products that are unsafe for consumption even before they pass their expiration date. Therefore, food manufacturers must employ reliable leak testing systems in their packing lines to avoid such issues.
Package Leak Testing Technologies
Underwater Leak Testing
During underwater leak testing, the packages are submerged underwater in a closed transparent container and put under a vacuum. Leaks are located by the bubble formations that rise from the suspected leak location. Although this method can precisely identify the location of leaks, it depends on the operator to decide whether the package leaks. Furthermore, a package that has undergone testing cannot be reused as it will be damaged during the test.
Pressure decay testing
The vacuum decay leak tester requires a package to be put into a sealed chamber under a controlled vacuum. A leak is identified if the chamber takes longer than expected or never reaches the preset vacuum level. This semi-automated leak testing technique can detect even fine-sized leaks, usually represented by the rapid pressure decay towards atmospheric pressure, even after the vacuum stabilization is turned off. Depending on the maximum permitted leak rates and package kinds, this test can also be pre-programmed to suit different types of packaging and products.
Optical Laser-Based detection system
A relatively new technology, the optical laser-based detection system allows manufacturers to verify almost all MAP-based packaging in the manufacturing line to achieve 100% quality testing. This test applies to MAP-based packaging that uses CO2 as its filling gas. This system sends a laser beam with a narrow wavelength range in the infrared band to the detector. Leaks can be measured by how much of a specific wavelength is absorbed by the CO2 gases. CO2 in the test chamber signals a leak for packages that employ CO2 as a filling gas.
Quality control and seal testing in the packaging line
Tens of thousands of items are moved through each packaging line each minute in a production setting. Manufacturers in the packaging sector who wish to include leak testing as a regular quality control procedure must first identify their requirements before they can choose from the various package leak testing methods available.
For instance, if the manufacturers want to test all products, a laser-based detection system will work well because it can carry out automated, speedy, accurate leak testing without interfering with the production line. This strategy, however, can prove to be initially pricey if the manufacturing facility has multiple production lines. Additionally, it is constrained because it is only applicable when CO2 is used as the filling gas.
On the other hand, underwater leak testing will be the preferred system if the manufacturers need to locate the leak. However, they need to prepare for the possibility of erroneous judgment as the leak quantification heavily relies on the operators, which has a high likelihood of happening after long hours of operation. They should also know that waste will be procured during manufacturing, as the tested packages must be thrown away after each test.
The Vacuum decay leak tester is a suitable option for manufacturers not looking for fully-automated leak testing systems. The procedure takes only 5 to 20 seconds to finish and the packages can be returned to the production line if they pass the tests. Operators also have the option to purchase additional systems for the production line if they need to conduct more tests to meet their quality checks. If they use this system to replace their underwater leak tester for testing high-value items, they can offset the cost of purchasing the equipment by avoiding waste.
Types of Packaging for Testing
Sealtick TSE6086b is a non-destructive vacuum-decay package leak tester used for testing leaks in food packaging. A few examples of factories that use Sealtick TSE6086b include manufacturers of canned foods, coffee beans, and dried snack products such as chips, biscuits, etc.
The Sealtick leak testers can be utilised in practically all package leak testing scenarios as long as the containers contain gases. As leak quantification is done by measuring the pressure decay rate, the test is not dependent on the types of gaseous agents used to fill the packages. As a result, it has a plethora of applications in numerous industries, including cosmetics, medical and pharmaceutical
The Sealtick leak testing systems are also available with different configurations for leak testing of different types of packaging such as cans, bottles and large, heavy bags. For can leak testers, the samples can be put into annuli specifically made for can leak testers rather than flexible bags. This configuration reduces the air volume in the chamber which is essential to get a better accuracy reading.
Industrial Capability
Due to the robust stainless-steel casing, the Sealtick leak tester offers long-lasting performance even when used in an industrial environment. The device’s internal memory stores all test results for a 30-day. Operators can easily export the stored data for analysis and quality traceability via USB or Ethernet.
Although the TSE6086b can effectively detect packing leaks without halting production, it cannot tell the operators exactly where the leak is located. Generally speaking, package leaks indicate equipment malfunction at any stage of the production process. These issues must be immediately resolved to avoid additional packages from leaking and ultimately interrupting production. Operators aware of the leak location will be better equipped to identify the problematic machinery and make the necessary adjustments.
To address this concern, using an underwater leak tester in conjunction with TSE6086b in the production environment can be helpful. Operators can insert the rejected packets from TSE6086b into the underwater leak tester to identify the leak’s exact location. Hence, the bubble leak tester, when employed as a secondary system, can help operators find the leak while TSE6086b can act as the primary instrument for testing the reliability of package seals.
Local Technical Expertise and Support
Having immediate access to expert technical assistance is crucial in the manufacturing and B2B industries since lengthy downtime brought on by system failure are costly for the business. The Sealtick leak testing equipment is developed and manufactured in-house in our manufacturing facility in Australia.
We also have technical experts with extensive knowledge and industry experience to support you with packaging leak testing in various industries. Please speak to one of our engineers at Sealtick via 03 9540 5100 to discuss your package leak testing requirements.
