Leaky modified atmosphere packaging is one of the most common causes of quality loss, customer complaints and food waste in the food industry. With the Leak-Master One, WITT Gasetechnik presents an in-line leak testing system which 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 CO₂-based vacuum testing method with infrared sensors, which is specifically designed to detect micro-leaks relevant to practical applications.
With a detection threshold of around 10 micrometers, the system identifies precisely those leaks that gradually compromise the protective atmosphere and often only become apparent as a quality issue at a late stage.
Individual inspection of up to 120 packages per minute
This is made possible by 12 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, in real time.
The Leak-Master One thus resolves a key trade-off in inline leak testing: previously either slow but highly sensitive methods, or fast but less accurate systems, were available. But now the Leak-Master One combines speed and precision at the individual package level for the first time.
Clear test results for every single package
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. This enables 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 to reliably meet the contractual quality requirements of retailers, avoid complaints and secure long-term supply reliability with major retail partners. Leaky packaging does not reach the market – customer losses can thus be specifically avoided.
For demanding MAP applications
The Leak-Master One is suitable for almost all CO₂-containing modified atmosphere packaging (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.
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Naresh Khanna – 10 February 2025
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