Alphapro

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Automatic leak detector

  • Fully automated
  • Measure leaks > 5 µm
  • Immediate digital data
  • Accurate analysis results
  • ISO 22000 & HACCP compliance
  • Operates without consumables
  • 3 years warranty
  • For inspection lines

The AlphaPro is a fully AUTOMATIC Leak Detector dedicated to flexible packaging for the Food, Pet Care and Cosmetic Industries. It has been specially designed for assembly line sample testing in Factories which handle large production volumes, and that have to follow Food Safety Management Systems according to ISO 22000 & HACCP.

To test products, divert samples from the production line to an inspection line where the AlphaPro has been installed, and the leak test is then performed without any human intervention whatsoever (it is a destructive test).

Full digital results are immediately available (the AlphaPro will measure leaks > 5 μm), visible on the screen, and can be instantly transmitted to the Manufacturing Process Control System or to a computer via a USB connection. Analyse the results on a pivot table, visualise the results on a Gauss chart on a separate optional monitor, set limits or stop production immediately should the packaging not conform to the pre-set parameters.

Automatic calibration check:
A calibrated leak is built-in the leak testing unit of the AlphaPro. The value of this calibrated leak is stored in the instrument’s memory (the leak is expressed in cc/mn at a given pressure in mB). The operator can compare the AlphaPro performance with the calibrated leak value at any time, and determine if recalibration is required.

If the flow rate of the AlphaPro at a given pressure is between the minimum and maximum limits, no further checks are needed, and you can continue to use your AlphaPro. If not, further investigation is required.

Warranty: 3 years.

Histogram displayed on the optional monitor.
1. Fully automated process and immediate digital data:

Your flexible packaging can be tested immediately and in real time, without any human intervention whatsoever (destructive test). Results are instantly transferred to the Manufacturing Process Control System or to a computer via an USB connection. You can set limits, stop production immediately should the packaging not conform to the pre-set parameters. Analyse the results on a pivot table in order to identify the area to improve. Histogram visualisation on a separate monitor is optional.

Histogram displayed on the optional monitor.

2. Accurate analysis results.

No more blocked needles compromising the results of your tests, no more guessing the sizes of the bubbles. Well adapted to packaging where there is little or no headspace (chocolate bar…), the AlphaPro will deliver accurate results to help you improve your process in a very short period of time.

3. ISO 22000 & HACCP compliance:

During the continuous improvement process of your ISO 22000 & HACCP review, identify flexible packaging related critical points, conduct root cause analysis, establish your critical limit, test, correct, verify & document easily with the AlphaPro. Avoid product recall by making sure your food is safe to be consumed until the last day of the shelf life.

4. Cost savings:

With the AlphaPro, consumables like septum and needles are no longer needed. In addition, you can reduce wastage by better controlling the seal(s) of your flexible packaging, optimize the thickness of your film and save costs (the thickest film is not necessarily the best for your product).

5. MAP packaging Control:

If your package food using Modified Atmosphere Packaging (MAP) with the AlphaPro, you can check that your products are within the acceptable leak range & that they will be preserved until the last day of the shelf life.

6. Brand protection and lasting taste for your products:

Avoid humidity and bacteria getting into your package and compromise the taste of your products. For potato crisps manufacturers, preserve the crispiness and pillow effect.

Optional monitor displaying an histogram.

15.6″ monitor with integrated calculator.

The optional monitor with integrated calculator displays the leakage results of the previous 100 tests. The Histogram shows the distribution of the results, and helps to understand if the production is experiencing an unfavorable drift.

OS: LINUX.

Size: 15.6″

Full results without selection.

Focus on results below 20 cc/min.

Right scroll.

The AlphaPro consists of 2 different units: an AlphaTower (patented perforating device) and a Leak Testing Unit. The AlphaTower and the Leak Testing Unit  are communicating via a PS/2 cable and a PU tubing.

  1. AlphaTower:

Patented perforating device.

OLED display 1,5 “.

Touch sensitive buttons for perforating depth.

Servo driven internal perforating thin conical stainless steel pointer.

Silicon bellows diameter: 15mm* (* other sizes / shapes: consult us).

Cantilever holder for free movement of tower.

  1. Leak Testing Unit:

The AlphaPro Leak Testing Unit operates according to flow measurement at a Constant Pressure following DIN 55508-1 of 01/02/2018.

Structure: steel and ABS.

Display: 3,5” resistive touch screen.

Alicat electronic pressure controller from U.S.A., 1000 mbar scale.     www.alicat.com

Alicat mass flow meter from U.S.A., 1000 sccm scale.

Microprocessor: embedded ATMEL2560, 16 Mhz.

Calibrated leak port.

Foot print: 260 x 250 mm     Weight: 10 Kg.

The AlphaPro is guaranteed 3 years.

Maintenance: No specific maintenance required.

We recommend that the calibration of each ALICAT is checked every 12 months.

Weight: 10 kg approx. unpacked, 12 kg packed for export.

Dimensions: Export packed = 55 x 34 x 20 cm.

All components ROHS.

HS Code = 820730 Tools, interchangeable; (for machine or hand tools, whether or not power-operated), tools for pressing, stamping or punching.

1/ Are there any other fully automated Leak Tester available on the market?

No, there are no Automatic Leak Testers available today, apart from the AlphaPro. The main reason is that presently, in order to perform a leak test on flexible packaging, you need to adhere a septum to the package and perforate it with a hollow needle, sometimes at an angle if there is no headspace. This operation can only be done manually. The AlphaPro works differently. It has a Perforating Tower that contains a solid thin conical stainless-steel pointer (the mechanism in the Perforating Tower is a worldwide patented invention), and does not need any septum. This invention enables the AlphaPro to be fully automatic, with no equivalent on the market today.

2/ Why do I need a special leak tester for flexible packaging? Are the leak testers available not suitable?

Most available leak testers would use a leak test method known as Pressure Decay, which measures the difference in pressure during the test. The problem is, that for flexible packaging, the Volume of the package is also changing during the test. And since Pressure x Volume is a constant, you cannot measure the leak accurately if both Pressure and Volume are changing at the same time during the test. The Pressure Decay is however perfectly suitable for rigid packaging. The AlphaPro is using the “Flow Measurement at a Constant Pressure” method according to DIN 55508-1 of 01/02/2018, particularly adapted to flexible packaging.

3/ Is there a risk that the package will be perforated totally, and the perforating pointer be damaged?

No, it is not mechanically possible that the perforating pointer will come in contact with the base, as it will stop 1 mm before.

4/ Who can assist me if anything goes wrong?

We can assist you by remote video conferencing if there is no Service Company in your area / Country. This would be during normal office hours. We are located in Singapore (GMT + 8). It is possible to support you outside of normal office hours by prior arrangement.

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AlphaPro introduction01/06/2021
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