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Can the sugar free variant use the existing cap?


Project details

Introduction of a sugar free variant
Fast and accurate measurement
Bottle with a plastic pouring cap with lip
R&D Quality

Related cases

Every week the developers of Oxipack receive phone calls from R&D managers, product developers, packaging technologist, engineers and packaging development managers. These people want to improve their leak detection systems or are enquiring about whether a new packaging concept can be tested.

The company wants to know for sure:

  • Does the cap leak and if so how much precisely?
  • What is the band width of the variation?
  • What are the consequences as regards shelf life?

This needs to be tested. But how? The bubble test method used by the company is not accurate enough. So there seems to be no answer to this difficult questions.

That is until an R&D colleague who has another leak detection question gets in touch with Oxipack. The member of the R&D department is amazed by the precision of the readings.

“If you are able to measure such miniscule pressure differences, then perhaps you may also be able to find a solution for our pouring caps!”

That same afternoon a prototype that has been rapidly produced shows that leak testing the caps is possible. A day later the Production and Site Managers pay a visit to see for themselves how it all works.

Testing a sample run
A week later and Oxipack has already started a series of tests using an adapted version of one of the standard leak testers. During the sampling run, the permeability of 2,000 bottles with the pouring cap are tested. This lays down the baseline in comparison with the current method of measurement. It allows a very precise assessment of the quality of the packaging machine. If the Oxipack leak detection equipment indicates a difference, then these are the actual differences caused by the production. They are not due to the measuring equipment, tester or method.

Airtightness within limits
After a couple of days of testing it is clear that the seal does in fact let a tiny little bit of air in, but is sufficiently airtight. Combined with data from microbiology tests it can be confirmed that the current quality of the seal will have no consequences as regards shelf life. Thus the company does not have to change the packaging machine and can continue with the present means of manufacturing and testing. The company can do this in the safe knowledge that airtightness has been proven to fall within the prescribed parameters.

How do we reduce the percentage of leaks?
This percentage can only be reduced if the exact figures are known. When trying to optimise efficiency a proper analysis of the actual percentage of leaks is vital. Actually finding out how many leaking packages are being produced is difficult to do.
Closer, critical investigation shows that the percentage of leaks is always greater than expected. All kinds of factors play a part and views on leak detection vary. Nobody wants to stop a production line, but the consequence further down the line, is that large numbers of packed products will need to be destroyed.
Attack the problem at source: the packaging machine. If you know exactly how many leaking packages are being produced then you will very quickly have the packaging machine under control and the percentage of leaks as well. Systematic leaks can be traced using systematic sample testing. Random leaks can only be detected using 100% leak detection.

What savings can be made with leak detection? Leaking packaging always causes losses in the whole production chain. Which might even damage your brand reputation. Leak detection however is a tool that results in savings.
Savings of one to two tonnes in euro’s for each packaging line per year are possible in the food products sector. The calculations vary according to circumstances and depend on the product and raw materials used. Is the current packaging destructively tested for leaks? If so the savings are even greater.

Would the number of staff needed, change due to in-line leak detection? When using 100% leak detection less people are needed for final checks. The operator spends less time on checking and has time to deal with other tasks. The leak detection equipment results in no additional stoppages due to maintenance.
In the first few weeks the equipment will regularly detect leaking packaging. It will look like more packages are being found with leaks than before. The cause of the leak will have to be traced in order to solve the problem with the packaging machine. The Production Manager should take this into account. After a couple of weeks the packaging process will have improved so much that leaking packaging will only be detected once in a while. And that is why you chose for in-line leak detection.

Is 100% leak free packaging possible?No, it just is not possible. There will always be tiny leaks and it is hard to predict where and why they occur.

  • It could be a random event, when the product just happens to come into contact with the edge of the seal.
  • Other leaks develop systematically. Then every twelfth package has a leak, a whole pallet or a certain corner of a seal. There could be a small pip on a roller that the foil runs over. Or perhaps one of the twelve sealing jaws in the vacuum applyers does not heat properly.

Are there more packages leaking than before?The “lean” production methods in the food processing sector seem to increase the number of leaks. Stocks are kept to a minimum. In the past, the same product would roll off the production line continuously for a whole week, now the same packaging production line will switch between all sorts of flavours and umbrella brands. Due to this change the production line does not run continuously. After a few shifts the packaging machine is converted to produce packaging using other paper covers or a single foil wrapper. This could be for another country or subsidiary brand.
As a result of lean production methods the machine has to be restarted a few times every week. And the start up process normally entails a run with a series of leaking packages. As the packaging production line has to get up to speed, the sealing process takes longer. This means the product material is exposed to high temperatures for a longer period. This results in a higher percentage of leaks.

How long does it take to recoup the investment?The answer depends on another question: what does leaking packaging cost the company?
Is this difficult to find out? Just ask yourself this:

  • What does it cost if a production run of 12 hours has leaks?
  • And what is the cost of four hours production for repackaging?

The investment in stand alone leak detection can be recouped in a few months.
In-line leak detection equipment pays for itself in one to two years.
It can sometimes be hard to present a business case if you do not have the exact figures relating to down-time or leak percentages. We can help you with the calculations.

Is it a dry measurement method?The Oxipack leak test equipment works by measuring pressure. Water is not used in this process and no detection gases are used. It is a clean, dry and extremely precise test method. This applies to both the stand alone leak testers and in-line leak detection systems. This form of testing allows you to get rid of the not so hygenic water immersion tank from the production area.

Can the stationary leak tester be used continuously?Need to check large quantities of packaging at a high speed? The Oxipack testing equipment is ideally suited to this purpose. The Stationary Leak tester can be deployed for offline testing in a lab situation or for random sample testing during production. Where necessary, it can run continuously.

What does in-line leak detection mean for the operator?Introducing 100% leak detection demands some extra work from the operator initially. The first weeks will be more demanding; the system will detect leaking packaging more often than expected. That means the operator will have to trace what is causing the leaks. The operator will also have to handle the rejected packaging. Once the packaging machine has been set up for optimum performance, the number of leaks in the packaging will drop sharply and things will be easier for the operator.

Is it difficult to operate the stand alone leak tester?Quite the opposite, operating is simplicity itself. Open the cover, put the packaging in, close the cover and press the green button. The equipment does the rest. If the green light comes on, that means the packaging has no leaks. If the red light is on then the packaging has a leak. A simple but a reliable test method.

How often does the leak tester break down?” Almost never. The Stationary Leak Tester is a robust device that can handle 500 to 1000 leak tests a day. Breaks downs are very rare. Most importantly the leak tester needs very little maintenance. An occasional clean with a damp cloth is all that is needed. An annual service is sufficient to check the condition of the membranes and filters.

What do operators think about working with the Stationary Leak Tester?What do operators think about working with the Stationary Leak Tester?
Operators can carry out their work to an optimum level with the Stationary Leak Tester. The fact that this is a “dry” test method is greatly appreciated. This is certainly true if the operator works in a chilled environment. We often hear operators say:

“it’s ideal, I no longer have to put my hands in the immersion tank, this equipment is excellent”.

Because people like using the equipment, the method for taking measurements is made use of in the agreed way.

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