Leak Detection Equipment for Flexible Packaging

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    The range of products manufactured by Astaara has been specially developed for flexible packaging. We are using the only method suitable for this application, “Flow Measurement at a Constant Pressure”, as instruments using pressure drop do not work on products whose volume changes during the test.

    In addition to accurate and reliable micro-leak detection (from 5 microns), Astaara products offer unique advantages:

    1/ Altitude simulation: we have developed a test to measure the effects of altitude on flexible packaging.  With the AlphaLab, test the resistance of your packaging up to 20,000 feet, discover at which altitude it starts leaking. This simulation is exclusive to Astaara.

    2/ When leak tests are performed on products where there is little space inside the package between the product and the film (headspace), the hollow needle gets stuck in the product and clogs very frequently, and the results are not reliable. Astaara has developed and patented a unique perforation method that prevents this blockage: the AlphaTower.

    3/ The range of products manufactured by Astaara is today the one and only way to AUTOMATICALLY perform sample leak detection on flexible packaging without any human intervention. Food, Pet Care & Cosmetic Manufacturers are now able to automatically manage leak detection and analyse immediate digital tests results with the AlphaPro.

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    The Astaara advantages

    We detect leaks as small as 5 microns, and we use the only suitable method for flexible packaging: flow measurement at a constant pressure. The pressure drop measurement method does not work, because the volume of the package changes during the test.We offer immediate leakage measurement, as opposed to immersion methods (bubble test) which only show the presence of large leaks without measuring them.In addition, Astaara products are simple to use, and with fully pictorial displays. There is no over-engineering, and we provide benefits that are totally adapted to your application.

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    Food manufacturers invest huge amounts of money in packaging their products hermetically, and assure their customers that they will be preserved until the expiry of the use-by date. But if the food is transported by air, it will be subjected to a significant pressure difference, which can create leaks not visible to the naked eye, and that will remain after the aircraft has landed.The AlphaLab, the GammaLab and the AlphaLeakTester accurately measure the altitude at which your packaging will start to leak, and we test up to 20,000 feet (6.098 meter’s).ASTM D6653 specifies that flexible packaging should be subjected to an altitude of between 14,000 and 16,000 feet for one hour, to see the effects of altitude on the hermeticity of the packaging. Astaara products enable you to perform this test in your laboratory.Watch the effect of altitude on 6 bags of chips transported at 12,500 feet:Chips transported at 12,500 feet

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    Traditionally, manufacturers use a thick film, hoping to maximise the sealing capacity. However, the thickest film is not necessarily the best in terms of leakage. With the Astaara Leak Tester, you will be able to select the best packaging material, and perhaps discover that a thinner, cheaper film may be more suitable.Consumables for leak & O2 traditional tests are mainly comprising of septa, which takes the form of a sticker that is adhered to the flexible packaging to be tested, and a hollow needle. A septum can only be used once. A leak septum is 2.5 times more expensive than a O2 septum. With the AstaaraTowers, consumables like septa and hollow needles are no longer needed. Each perforating tower has an integrated solid thin conical stainless-steel pointer which replaces the hollow needle used today, therefore, operates fully without any septum.

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    If you have invested in MAP, it makes sense to ensure that your valuable gas will not leak after your product is manufactured. Astaara Leak Testers will help you to minimise this risk.Implement the sealing’s integrity control of flexible packaging during the next ISO 22000 & HACCP review using the continuous improvement process. The sealing integrity of the flexible packaging being a Critical Point, the Astaara product range will assist you to identify the value of its Critical Limit, record and monitor the tests results. This will help to find the root cause of leaks above the Critical Limit, therefore enabling corrective action to be taken.It is important to point out that leakage testing by immersion (or bubble testing) does not allow compliance with ISO 22000 / HACCP, because critical control points need to be measured, and there is no measurement in bubble testing, just an observation of the presence of significant leakage.

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    Thanks to the AlphaPro, flexible packaging can be tested immediately and in real time. Simply select and divert product samples from the production line to an inspection line, and perform AUTOMATICALLY a leak test without any human intervention whatsoever (i.e. a destructive test).Full digital results are immediately available (leaks > 5 microns are captured) and are instantly transferred to the manufacturing process control system or to a computer via an USB connection.

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    After manufacturing, products may be subjected to a certain number of harmful external factors, for example changes in differential pressure during air transport, extreme temperature changes, excessive compression due to manipulation, etc. etc… A mild leak may therefore increase and become excessive.As a result, humidity and bacteria could infiltrate the package and compromise the taste or the integrity of the content. For seafood packed under Modified Atmosphere Packaging (MAP) for example, the product may become unsafe for consumption.The Astaara range of products will assist you to monitor very precisely the reliability and consistency of the flexible packaging sealing integrity, therefore avoiding undesirable consequences.

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    Food production Industry


    • Food Industry.
    • Pet-care Industry.
    • Cosmetic Industry.
    Packaging Machine and System Integrators

    Packaging machine builders
    (OEMs) & system integrators:

    • HFFS (Horizontal Form Fill and Seal machine).
    • VFFS (Vertical Form Fill and Seal machine).
    • Stick Pack machines.
    Food Safety expert in Lab

    Consultants & Laboratories:

    • Food Safety expertise.
    • ISO 22000 & HACCP consulting.
    • Food Packaging Automation Consultants.
    Leak Detection Equipment

    Food packaging inspection, Control Equipment Distributors
    & Resellers of:

    • Metal detectors.
    • Checkweighers.
    • Seal checkers.
    • X-rays machines.