Highly sensitive inline leak testing

WITT Gas Controls introduces the LEAK-MASTER ONE, an advanced inline system designed to detect micro-leaks of CO2 in modified atmosphere packaging. One of the most common causes of food quality loss, customer complaints, and waste, these leaks often go undetected until it is too late. With the LEAK-MASTER ONE, WITT Gas Controls presents an inline leak testing system that, for the first time, combines two previously conflicting requirements: high-precision leak detection in the micrometer range and clearly traceable individual testing at full packaging speed.

The LEAK-MASTER ONE is integrated into the MAP packaging line and checks products individually (one by one) for leaks. It is based on a vacuum testing method with infrared sensors, specifically designed to detect micro-leaks relevant to practical applications. With a detection threshold of around 10 micrometers, the system accurately identifies precisely those leaks that gradually compromise the protective atmosphere and often only become apparent as a quality issue at a later stage.

This is made possible by twelve mini vacuum chambers operating in parallel, which are loaded fully automatically using pick-and-place robotics. The system achieves a testing capacity of up to 120 packages per minute, thereby enabling, for the first time, highly sensitive leak testing of individual packages directly within the running process.

The LEAK-MASTER ONE thus resolves a key trade-off in inline leak testing: whereas previously either slow, highly sensitive methods or fast but less accurate systems were used, the LEAK-MASTER ONE combines speed and precision at the individual package level for the first time.

The key process advantage lies in the clear and reproducible identification of every single leaky package. Each leak is detected and documented on a product-by-product basis, enabling targeted removal from the production line. For quality assurance and production, this means fewer follow-up checks, significantly less unnecessary waste, and higher output.

At the same time, the LEAK-MASTER ONE helps food manufacturers reliably meet the contractual quality requirements of retailers, avoid complaints, and support long-term supply reliability with major retail partners. Leaky packaging does not reach the market, allowing customer losses to be more effectively avoided.

The LEAK-MASTER ONE is suitable for most modified atmosphere packaging containing a minimum of 10% CO2 (excluding cases with a high oxygen content >20.9%) and for applications with high standards of process reliability and quality. Typical applications include meat and cheese products, convenience foods, fresh ready meals, baked goods, and other MAP applications.