Non-destructive, multi-product seal integrity and leak detection for flexible and semi-rigid packaging
With 1-up, 2-up, 3-up and 6-up test layouts, the PakScan gives manufacturers the flexibility to test different packaging formats and sizes using one machine. Up to six packs of the same format can be tested in a single cycle, with an individual pass/fail result for each pack.
Flexible testing for different pack formats
Flexible packaging presents different challenges for seal integrity and leak testing. Pack size, material, seal design and headspace can all influence test performance.
The PakScan adapts to these requirements through configurable layouts for different pack formats and sizes. Using Force Decay technology, it detects pinholes, weak seals, channel leaks and gross defects in sealed, non-porous packaging without destroying packs. This allows packs that pass the test to remain available for further use or downstream processes.
The result is an objective, repeatable and operator-independent test method for laboratory testing, in-process control and quality assurance.
Packaging formats and test areas
The PakScan is suitable for flexible packaging made from non-porous materials, including PVC, PVDC, Aclar, aluminium foils and laminates, containing dry products or solid components. It can accommodate a range of packaging formats, including pouches, sachets, stick packs, transdermal patch packs and semi-rigid lidded trays.
The table below shows the maximum test area for each configuration:
| Configuration | Test Area |
|---|---|
| 1-Up | 304 x 275 x 50mm |
| 2-Up | 304 x 136 x 50mm |
| 3-Up | 100 x 275 x 50mm |
| 6-Up | 100 x 136 x 50mm |
Individual load cells can be activated or deactivated as required, allowing manufacturers to use only the test positions they need, for example, testing five packs in a 6-up configuration.
Multiple PakScan systems can also be connected to a shared database, allowing the same validated test method to be used across multiple machines and supporting consistent seal integrity testing in higher-throughput manufacturing environments.
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Features
Non-Destructive Testing
- Detects pinholes, weak seals, channel leaks and gross defects
- Tests sealed, non-porous flexible packs and semi-rigid trays
- Individual pass/fail result for each active pack position
- Packs that pass can remain available for further use or downstream processes
Objective Results
- Force Decay technology
- Deterministic and operator-independent test method
- Defect detection as small as 10µm, pack and material dependent
- Test times from as little as 10 seconds, pack and material dependent
Practical Operation
- Front-loading drawer for easy loading and unloading
- Compact footprint for use closer to production areas
- Simple touchscreen interface
- Suitable for low-headspace pouches and sachets
Data and Connectivity
- Secure storage, review and export of test, recipe and batch data
- MESConnect / OPC connectivity
- Can form part of a 21 CFR Part 11 compliant system
- Active Directory integration via LDAP/LDAPS
- Flexible reporting available on request
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Technical Spec
- Pack Type
Sachets, pouches, stick packs, semi-rigid trays (flexible, non-porous materials) - Test Area
See table above - Leak Detection Sensitivity
As low as 10 micron (pack and material dependent) - Test Cycle Time
From 10 seconds (pack and material dependent) - Operation
Semi–automatic - Machine Construction
Anodised Aluminium, acrylic and polyurethane case - User Interfaces
13.3″ touchscreen (1920 x 1080 resolution) - Utilities
– Electrical: 110/230 VAC, 50/60 Hz, Single Phase – Air: Min. 200L/min at 0.6Mpa [ISO8573-1:2010 CLASS 2]
- Configuration
2x USB Ports, 1x Ethernet Port - Tooling Changeover
Approx. 1 minute - Audit Compliance
Can form part of a 21 CFR Part 11 compliant system - Machine Dimensions
536mm (L) x 584mm (W) x 520 (H) - Machine Weight
73kg - Shipping Weight
170kg - Warranty
Supplied with a 12-month warranty. (Service Level Agreements and/or extended warranties are available for additional support).
- Pack Type
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Application
Laboratory Testing
Supports packaging development, feasibility testing and test method development across different pack formats, materials and seal designs.
In-Process Control
Enables seal integrity testing closer to production, helping manufacturers identify packaging issues earlier and investigate potential process issues before larger quantities are affected.
Quality Assurance
Integrates objective, repeatable seal integrity testing into quality assurance procedures, with individual pass/fail results and securely stored test data to support quality documentation.
Reduce Production Rejects
More frequent seal integrity testing can help identify packaging defects earlier, allowing manufacturers to investigate potential process issues before larger quantities of faulty packs are produced. This can help reduce rejects, product loss and packaging waste.
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Benefits
Non-Destructive Testing Supports Waste Reduction
- Clean and dry testing does not destroy the product or packaging
- Packs that pass remain available for further use or downstream processes, where site procedures allow
- Earlier detection of packaging defects can help reduce product loss, rejects and packaging waste
Objective, Repeatable Results for Each Pack
- Individual pass/fail results support clear and consistent quality decisions
- Operator-independent Force Decay testing reduces reliance on subjective assessment
- Securely stored test, recipe and batch data supports data integrity and quality documentation
Flexibility Across Different Products
- Configurable layouts allow different pack formats and sizes to be tested using one machine
- Tests up to six packs of the same format in a single cycle
- Individual test positions can be activated or deactivated to match production requirements
Earlier Detection of Packaging Issues
- Fast test cycles support more frequent seal integrity testing closer to production
- Earlier detection allows manufacturers to investigate potential process issues before larger quantities are affected
Efficient Day-to-Day Operation
- Front-loading drawer and touchscreen interface support straightforward operation
- Approximately one-minute tooling changeover helps reduce time between products
- Compact footprint allows the machine to be positioned closer to production areas
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Force Decay
How does Force Decay testing work?
A flexible package is placed within a tool set which comprises of a strain gauge load cell, which in turn is housed within a vacuum test chamber.
Vacuum is applied to the test chamber and under this vacuum the flexible package will expand and generate an expansive force in response to the vacuum.
The strain gauge load cell measures the expansive force over time to determine if the package has a gross leak, micron leak or has no leaks.
- If there is a gross leak, no expansive force is measured.
- If there is a micron leak, an expansive force is initially measured but will start to reduce over time as the pack lets air escape into the vacuum chamber.
- If the pack is good it will expand under vacuum and remain inflated and in turn generate a constant force measurement over time.
To ensure the integrity of the pack is not affected or does not burst, a force reaction/restraining plate is used to prevent full expansion.
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