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Continuous Monitoring of Headspace Gas at the Point of Pack Closure on Flow Wrap and Bagging Lines

Continuously monitors % O2 or % O2 & % CO2 content of the pack headspace gas, at the point of pack closure – checking 100% of production in realtime.

Easily installed onto new, or existing gas flushing, flow wrap, or bagging packaging machines. The GasSave function automatically optimises the volume of gas consumed, resulting in reducing gas wastage and production costs.

The test data can be automatically downloaded to Paperless QA software – consigning offline checks to a verification role.

Process The Dansensor® MAP Check 3 continuously draws a gas sample from within the film tunnel, or forming tube, at the gas/air interface. The sample is passed through the Dansensor Zirconium O2 sensor and Infrared CO2 sensor. A continuous stream of realtime test results are compared against the target values for that specific product. The flow of flushing gas is then trimmed continuously, to maintain test values within the tolerance range.

Automatic Line Stop If the % O2 in the pack cannot be achieved by adjusting the gas flow, then the packaging machine is automatically stopped. This avoids producing non-conforming product. When newly installed, most users see a 20 – 50% reduction in gas consumption.

Significant benefits from on-line monitoring When flushing with a gas containing CO2, the online results are a more consistent and accurate indication of the real % CO2 within the pack, compared with offline checks. Carbon dioxide is water and fat soluble and can be very rapidly absorbed into the product. Even a short delay in carrying out an offline check can produce a less accurate result. Online checks help avoid having to strip out product that has been incorrectly designated as “out of specification”.

Helps maintain a safer working environment. The MAP Check 3 can help an organisation meet their compliance with the Health & Safety Executive’s The Control of Substances Hazardous to Health Regulations EH40. Work place limits are set for atmospheric carbon dioxide and the GasSave function of the MAP Check 3 helps to reduce elevated levels of CO2 on the production floor.

Environment and the reduction of packaging waste are high on the agenda of the Food Industry. The online, non-destructive testing of the MAP Check 3, helps to further reduce the packaging waste generated in offline testing. For example, each production line testing 6 packs every 30 minutes on a double day shift and a 5 day working week, will send 67,200 packs to landfill each year, plus wasted product.

Oxygen Sensor Carbon Dioxide Sensor
Key features Fast and accurate oxygen sensor 0 – 100% range Temperature controlled dual beam infrared carbon dioxide sensor 0 – 100% range
Accuracy ± 0.01% absolute range below 1% ± 1% relative in range above 1% ± 0.5% absolute ± 1.5% relative reading
Heating time 10 minutes 8 minutes
Models Available with LCD display or as “Black Box” without display
Connections 2 x RS232C, LAN 10 / 100 Mbit (Modbus TCP), current or voltage output, 24 VDC logic for start / stop of machine and alarms
Power supply 103 – 132 / 207 – 264 VAC (auto ranging), 47 – 63 Hz
Gas media Any mix of dry oxygen, carbon dioxide or nitrogen (0 °C to +50 °C gas temperature)
Gas inlet pressure 2 – 10 bar, depending on back pressure and flow
Pressure drop Example: 1 bar at 10 bar input pressure
Gas flow 6 – 500 l/min
Flow measuring Total and daily consumption
Number of inputs 3 (channel priority: selectable 1-2-3 or 1-2-1-3-)

Further Benefits and Options
To streamline installation, Tendring pacific offers:

  • Fittings Kits – 2 versions N2/CO2 only & O2
  • On-site installation & training by our installation engineers
  • IP 54 Stainless Steel Enclosure for use in both wet & dusty environments
  • Warranty Upgrade
  • Annual Service Contracts & Preventative Maintenance Contracts
  • Plantstats QC Pro, paperless QA software for data collection with email/SMS alerts
  • Buffer Tanks installed for complete central mixing capability
  • Dansensor MAP Mix Provectus – for total control

Contact Our Sales Team

01223 492083

Dansensor MAP Check 3 Online Headspace Gas Analyser

Dansensor MAP Check 3 Preventative Maintenance Guide

'How To' Videos for the Dansensor MAP Check 3

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If you’d like to see the Dansensor MAP Check 3 Online Headspace Gas Analyser in action, please contact 01223 492083 or

Dansensor MAP Check 3 Online Headspace Gas Analyser