Presentation on theme: "Seal-Scan™ Non-Destructive Inspection Technology for Retort Pouches"— Presentation transcript:
1Seal-Scan™ Non-Destructive Inspection Technology for Retort Pouches Tony StaufferPackaging Technologies & InspectionTuckahoe, New YorkPTI Inspection Systems:
2Seal-Scan™Only Seal Inspection system that is:Non-destructiveNon-invasiveNon-contact
3Applications of Seal-Scan™ Ultrasound Inspection Analyzes seal quality of pouches and flexible packagesCharacterizes bonded materialsWorks with all materials: film, alu, paper, or compositeProcess controlQuality controlResearch and development
4Produces a single linear scan in less than 1 second Seal-Scan™Produces a single linear scan in less than 1 secondDigital pouch seal image in less than one minuteImages and characterizes bonded materialsHelps in process optimization
5Seal-Scan™ Principle of Through Transmission Ultrasonic SignalSEALTransmitterReceiverPouch seal or package material is placed between ultrasonic transmitter and receiver
6Ultrasonic SignalUltrasonic waves propagate through single or multiple layers of well bonded materials.Transition through different mediums causes reflection of sound waves and reduces/eliminates signal strength.
7Seal-Scan™ Technology Ultrasonic signal is transmitted along the X-axis through seal and signal is recorded.Signal measurement correlates to color gauge, creating high resolution image of seal structure and quality.
8Seal-Scan™ Signal Scale Opto Acoustic Image The colored gauge represents the scan signal measurement.Pink is low signal, green is normal signal (good seal), purple is high signal.Total 6000 grades of color are used.
9Scanning Modes L-Scan produces a graph of the signal and summary data. C-Scan produces an ‘Opto-Acoustic’ imageand summary data
10Pass – Fail Criteria and Data Integrity Pass – Fail limits are set for the average, minimum, maximum, and standard deviation of the signal measurements,All results are recorded using the system’s data log.
13C-Scan statistics of moving window C-Scan Analytical Tools10 mm135 mm16 mm6 mm3.5 mmC-Scan statistics of moving window
14Optimizing the Sealing Process Seal-Scan™ serves as an analytical tool to determine optimal sealing conditions; e.g. temperature, dwell time, etc.Variation decreases with increasing temperature.Optimal Sealing Temperature
15Material AnalysisHDPE exhibits better sealing uniformity and quality at higher temperatures.TYVEK® exhibited weaker bonding at higher temperatures.105 C HDPE C HDPE C HDPE C HDPE C HDPE128 C HDPE C HDPE C HDPE C HDPE C HDPE108 C TYVEK C TYVEK C TYVEK C TYVEK C TYVEK134 C TYVEK C TYVEK C TYVEK C TYVEK C TYVEK
16Seal-Scan™ and Peel Strength Testing BackgroundPouches with peelable seals were tested.Peel strength test was performed on specific area of seal sample, approximately one-inch.Seal-Scan™ C-Scan mode analysis of entire length of seal was performed.Results confirm direct correlation of both methods.
17Seal-Scan™ and Peel Strength Testing The Standard Deviation of the ultrasound signal correlates to the peel strength of a peelable seal. Seals with more variation in the quality of a sealed area will be easier to peel than a seal area that is uniform. If a seal has strong points of bonding but exhibits high variation, the peel strength of the seal will be less.
18Good Seal Profile(Film-Pouch) C-ScanSeal Quality HistogramSeal width profileSeal Width Data, mmAvgMinStD8.27.00.7L-ScanL-Scan Statistics, % Signal ValueAvgMinMaxStD33.127.741.21.9Test results to be compared against Pass-Fail reference values.
19Defective Seal Profile (Alu-Pouch Channel Leak) C-ScanSeal Quality HistogramSeal width profileSeal Width Data, mmL-ScanAvgMinStD126.96.36.199L-Scan Statistics, % Signal ValueAvgMinMaxStD1.7-80.510.08.0Low average and minimum, with high standard deviation.
20Case Study Heinz Douarnenex, Fr Defect Profile - 30,000 pouches were visually inspected 100%Defect typeCommentNumber detectedReject RateLeakCritical3.01%Corner channelMajor or critical4WrinkleDepends on height8.03%InclusionAir bubblesDepends on size19.06%WavesUsually minor12.04%BlisterMinor86.29%Fold11Total defects147.49%
21Case Study Heinz Douarnenex, Fr Typical Defects LeakCriticalCorner ChannelCriticalCritical(may vary)WrinkleMinorInclusionCritical
22Case Study Heinz Douarnenex, Fr Typical Defects Air BubblesCriticalCriticalMinorWavesCritical
23PTI-550 Online Pouch Inspection Pouches go onto Seal-Scan from pouch machine at 60-70/Minute
24PTI-550 Online Pouch Inspection 1. Pouches are dropped into a special conveyor2. Pass through PTI Seal-Scan Ultrasonic-head3. Accepted or rejected
25PTI-550 Online Pouch Inspection Pouch Seal is guided through the Seal-Scan™ Head
26PTI-550 Online Pouch Inspection Seal-Scan Head with Operator interface
29Channel Description Cause An area of non-bonding across the seal that will generally leakCauseSealing bar settings were not correctly set (temperature, pressure and/ordwell time.)Contaminants may be present during seal formation.
30Compressed Seal Description Cause Any separation of laminates in seal area. Material bond strength isquestionable in defect area. Visual evidence of overheating such asbubbles.CauseSealing bars were too hot during seal formation.Material bond strength is inadequate.
31Contamination Description Cause Foreign material is trapped in seal. Retort pouches will have noticeableraised areas in seal where sealing bar sealed over contamination.CauseSeal area was contaminated during filling stage.
32Crooked Seal Description Cause A seal that is not parallel to the cut edge of the pouchCausePouch was misaligned in the sealing jaws.
33CutDescriptionA breach of all layers of the laminate, where the hermetic integrity of thepackage was compromised.CauseEquipment damage or “scrap” between laminate plies during formation.Pouch contacted sharp edges of other pouches or equipment.Pouches were abused during online or post-process handling.
34Delamination Description Cause Separation of laminated materials – can occur before or after retortprocess. Delaminations ultimately affect seal strength through lifecycle/distribution process.CauseIf occurring at the seal, bars were too hot during seal formation.If during retort process, residual air in the pouch was not controlled toeliminate pouch expansion during retorting.
35Incomplete Seal Description Cause Seal area does not extend completely across the width of pouch.CausePouch was not positioned correctly in sealer and sealing bar.
36Narrow Seal Description Cause Container seal area has no margin of safety to accommodate seal creepor wrinkles.CauseDefective sealing bars reduced seal width.Defects that cross seal, seal creep or mechanical separation reduce sealwidth.
37Non-Bonding Seal Description Cause Sealing films fail to weld during sealing process. Defect appears as faintsealing bar impression on retort seals. Application of slight pressure toseal will cause failure.CauseSeal area was contaminated.Sealing bar settings were not correct (pressure/temperature/dwell time).
38Wrinkle Description Cause Material fold on one seal surface, caused when one seal surface is longerthan the other. Can also be a severe fold over both seal surfaces atsealing time.CauseSealing surfaces were not flat and parallel or were not tensioned.Various other irregularities in sealing bar or surfaces.
39Pouch Inspection Economics One technology useable for all materialsNon-Destructive, Non-InvasiveNo sample preparation,No special Inks, no added variable costsReplaces costly, low efficiency manual InspectionReduces/eliminates IncubationSaves product & packagesLong term quality trackingIntegrates into most pouch sealing machinesReal Time Process Control - allows immediate corrective actionIncreases line efficiencyGood return on investmentYou sleep better at night