Non-invasive quality control of MAP packages integrated in thermoforming packaging machines
Get fully residual oxygen content control and leak detection of all packages produced with thermoforming packaging machines. Until now, incorrect O2-content and leaks in food packages were identified by random inspection. Defective products were thrown away since most detection systems were invasive. GEA LeakCheck and GEA OxyCheck units help producers save food, packaging materials and time by analyzing a sensor-sensitive, fluorescent spot inside the MAP pack. Packages with the wrong oxygen levels or leaks can then be automatically rejected using, for example, a GEA CombiPick package sorting and converging system.
Main applications
The GEA LeakCheck and GEA OxyCheck in-line quality control systems verify the O2 content and integrity of packages for food products such as meat, meat substitutes, dairy or bakery products packed in a modified atmosphere after the form-fill-seal process.
Key benefits
Automatic testing of residual oxygen content and tightness of all produced MAP packs without losses
- Non-invasive technique based on fluorescent sensor-sensitive spot applied on inner surface of package film
- MAP pack seals and films remain unaffected saving large quantities of film and food product
- Fully integrated in the thermoformer
- Supply only packages with right residual O2 content and no leaks after the form-fill-seal process
Increased food safety throughout the whole production volume
- 100% process monitoring - all MAP packs are tested
- No sampling tests necessary, where typically only less than 1% of the packs produced are tested
- Reliable and precise system with no human error possible
- No negative impact on the production capacity
Significant time savings due to automated oxygen/leakage inspection process
- No more manual testing by hand or visual inspection needed
- Automatic rejection of defective packages
- No labor-intensive tracing and tracking of out-of-specification packs
Specifications
More details to GEA OxyCheck & LeakCheckVerification of oxygen content and package integrity of MAP packs
The inspection system consists of the following steps: The first O2 content measurement is taken by the GEA OxyCheck sensor installed right after the food packages leave the sealing station of the thermoformer such as GEA PowerPak or PowerPak PLUS. Further on, the GEA LeakCheck unit performs a stress test by applying compressed air pressure on all packs. After this, a second oxygen test unit re-checks the O2 content. A difference in results points to a leak in the respective package.
Unique sensor spot technology
GEA OxyCheck uses the fluorescent properties of a special material. The top web films carry the GEA OxyCheck sensor spot printed on the inside as part of each package lidding. GEA OxyCheck optical sensors installed on the thermoformer project a light onto these sensor-sensitive spots and measure the wavelength of the light that fluoresces from the material to accurately determine the O2 content.
Automated sorting while ongoing production
Packages that do not meet specification are automatically rejected by a single pack selector such as the GEA CombiPick. The automation of the detection and sorting processes keeps the form-fill-seal machine running even when there are defective food packages in the line. Detected packs, with incorrect O2 content or leaks, can be extracted with this pick-and-place system.
World's first non-invasive quality assurance system for MAP
Add-ons
Options to GEA OxyCheck & LeakCheckGEA CombiPick - automatic single pack selector and converger
As a combined single pack pick-and-place and converger system for end-of-line applications on GEA PowerPak and PowerPak PLUS thermoformer configurations, GEA CombiPick is a powerful add-on unit. Empty or defective food packages simply drop into a bin under the conveyor, while positively inspected products come out at the end in a clean line. In addition, this machine can merge up to six webs into a single-lane outfeed.
GEA OxyScan - compact non-invasive oxygen measurement device
With GEA OxyScan, a very compact oxygen measurement device designed to spot check MAP packages, you can verify the residual oxygen content over the entire product life cycle. This uses a fluorescent GEA OxyCheck sensor spot printed on the top web film as part of each package lid. The mobile scanner takes a high precision measurement. Packs can be re-checked while they are in the production facility.
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