Or How Not To Test For Leakers

During a recent site visit to a meat factory, we noticed that, despite having over 20 packing lines, they only intermittently tested for leaks during their 24/7 production, using a single bubble tank.

Operators placed finished packs in the bubble tank, walked away, and left them under vacuum for several minutes. When they returned, they would check for significant pack deflation and rework if necessary, or wipe down and send the packs to end-of-line packing. The results were recorded on paper.

This process is flawed for several reasons:

  • Subjectivity:
    • Operators make subjective decisions about whether a pack has leaked.
    • Even though the pack was left in the tank for a number of minutes, it means that micro leaks would not be detected, as they take some time to show under water
  • Waste:
    • Film is wasted with the unnecessary rework
  • Hygiene:
    • Under vacuum, micro leaks will suck in water into the packs, very slowly. If no leak is detected with the eye, water enters the bag and is a possible catalyst for product spoilage and unwell customers!
  • Data Integrity:
    • Results recorded manually can lead to loss or errors.

How We Were Able To Help and Reduce Their Customer Complaints By 95%
The customer agreed to used the Dansensor LeakPointer 3 for a two-week loan period and the results were more than impressive. Many more leaks were detected and which the traditional bubble tank method would have missed. This lead to a 95% reduction in customer complaints about leaking packs.

The Effective Way to Test For Leaks

Dansensor LeakPointer 3
The Dansensor LeakPointer 3 creates a pressure difference between the pack and the chamber, which is preset and specific to each pack size.

If there is a leak, the pressure difference causes the CO2 inside the pack to leak into the chamber, and the device detects this CO2 trace. Leaks through perforations as small as 50-micron can be detected.

The display shows a happy or sad face once the test is complete, providing a clear, objective indication of whether there is a leak.

Advantages of the LeakPointer 3:

  • Objective Testing:
    • The decision is made by the instrument, not the operator
  • Quick Results:
    • Testing time ranges from 10 to 35 seconds
  • Non-destructive:
    • If no leak is detected, packs can be sent through to end-of-line packing without damage
  • Paperless QA:
    • All test results are stored electronically and can be exported as a CSV file via USB, or LAN connection.

Customer Experience
The customer agreed to used the Dansensor LeakPointer 3 for a two-week loan period and the results were more than impressive. Many more leaks were detected and which the traditional bubble tank method would have missed. This lead to a 95% reduction in customer complaints about leaking packs.

Contact Our Sales Team

01223 492083
sales@tendringpacific.com

Common Mistakes When Checking For Leaks
Common Mistakes When Checking For Leaks
Common Mistakes When Checking For Leaks