Seal-Scan™ Non-Destructive Inspection Technology for Retort Pouches Tony Stauffer Packaging Technologies & Inspection Tuckahoe, New York PTI Inspection Systems: www.ptiusa.com 800.532.1501 Pti@ptiusa.com

Seal-Scan™ Only Seal Inspection system that is: Non-destructive Non-invasive Non-contact

Applications of Seal-Scan™ Ultrasound Inspection Analyzes seal quality of pouches and flexible packages Characterizes bonded materials Works with all materials: film, alu, paper, or composite Process control Quality control Research and development

Produces a single linear scan in less than 1 second Seal-Scan™ Produces a single linear scan in less than 1 second Digital pouch seal image in less than one minute Images and characterizes bonded materials Helps in process optimization

Seal-Scan™ Principle of Through Transmission Ultrasonic Signal SEAL Transmitter Receiver Pouch seal or package material is placed between ultrasonic transmitter and receiver

Ultrasonic Signal Ultrasonic 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.

Seal-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.

Seal-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.

Scanning Modes L-Scan produces a graph of the signal and summary data. C-Scan produces an ‘Opto-Acoustic’ image and summary data

Pass – 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.

Seal-Scan™ 525 Offline Analytical Equipment

C-Scan window statistics C-Scan Analytical Tools 10 mm 135 mm 128 mm 6 mm 3.5 mm C-Scan window statistics Modified L-Scan

C-Scan statistics of moving window C-Scan Analytical Tools 10 mm 135 mm 16 mm 6 mm 3.5 mm C-Scan statistics of moving window

Optimizing 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

Material Analysis HDPE exhibits better sealing uniformity and quality at higher temperatures. TYVEK® exhibited weaker bonding at higher temperatures. 105 C HDPE 105 C HDPE 105 C HDPE 105 C HDPE 105 C HDPE 128 C HDPE 128 C HDPE 128 C HDPE 128 C HDPE 128 C HDPE 108 C TYVEK 108 C TYVEK 108 C TYVEK 108 C TYVEK 108 C TYVEK 134 C TYVEK 134 C TYVEK 134 C TYVEK 134 C TYVEK 134 C TYVEK

Seal-Scan™ and Peel Strength Testing Background Pouches 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.

Seal-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.

Good Seal Profile(Film-Pouch) C-Scan Seal Quality Histogram Seal width profile Seal Width Data, mm Avg Min StD 8.2 7.0 0.7 L-Scan L-Scan Statistics, % Signal Value Avg Min Max StD 33.1 27.7 41.2 1.9 Test results to be compared against Pass-Fail reference values.

Defective Seal Profile (Alu-Pouch Channel Leak) C-Scan Seal Quality Histogram Seal width profile Seal Width Data, mm L-Scan Avg Min StD 9.4 3.5 1.0 L-Scan Statistics, % Signal Value Avg Min Max StD 1.7 -80.5 10.0 8.0 Low average and minimum, with high standard deviation.

Case Study Heinz Douarnenex, Fr Defect Profile - 30,000 pouches were visually inspected 100% Defect type Comment Number detected Reject Rate Leak Critical 3 .01% Corner channel Major or critical 4 Wrinkle Depends on height 8 .03% Inclusion Air bubbles Depends on size 19 .06% Waves Usually minor 12 .04% Blister Minor 86 .29% Fold 11 Total defects 147 .49%

Case Study Heinz Douarnenex, Fr Typical Defects Leak Critical Corner Channel Critical Critical (may vary) Wrinkle Minor Inclusion Critical

Case Study Heinz Douarnenex, Fr Typical Defects Air Bubbles Critical Critical Minor Waves Critical

PTI-550 Online Pouch Inspection Pouches go onto Seal-Scan from pouch machine at 60-70/Minute

PTI-550 Online Pouch Inspection 1. Pouches are dropped into a special conveyor 2. Pass through PTI Seal-Scan Ultrasonic-head 3. Accepted or rejected

PTI-550 Online Pouch Inspection Pouch Seal is guided through the Seal-Scan™ Head

PTI-550 Online Pouch Inspection Seal-Scan Head with Operator interface

PTI-550 Online Pouch Inspection

Packaging Technologies & Inspection Seal-Scan™ 525 Defect Gallery

Channel Description Cause An area of non-bonding across the seal that will generally leak Cause Sealing bar settings were not correctly set (temperature, pressure and/or dwell time.) Contaminants may be present during seal formation.

Compressed Seal Description Cause Any separation of laminates in seal area. Material bond strength is questionable in defect area. Visual evidence of overheating such as bubbles. Cause Sealing bars were too hot during seal formation. Material bond strength is inadequate.

Contamination Description Cause Foreign material is trapped in seal. Retort pouches will have noticeable raised areas in seal where sealing bar sealed over contamination. Cause Seal area was contaminated during filling stage.

Crooked Seal Description Cause A seal that is not parallel to the cut edge of the pouch Cause Pouch was misaligned in the sealing jaws.

Cut Description A breach of all layers of the laminate, where the hermetic integrity of the package was compromised. Cause Equipment 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.

Delamination Description Cause Separation of laminated materials – can occur before or after retort process. Delaminations ultimately affect seal strength through life cycle/distribution process. Cause If occurring at the seal, bars were too hot during seal formation. If during retort process, residual air in the pouch was not controlled to eliminate pouch expansion during retorting.

Incomplete Seal Description Cause Seal area does not extend completely across the width of pouch. Cause Pouch was not positioned correctly in sealer and sealing bar.

Narrow Seal Description Cause Container seal area has no margin of safety to accommodate seal creep or wrinkles. Cause Defective sealing bars reduced seal width. Defects that cross seal, seal creep or mechanical separation reduce seal width.

Non-Bonding Seal Description Cause Sealing films fail to weld during sealing process. Defect appears as faint sealing bar impression on retort seals. Application of slight pressure to seal will cause failure. Cause Seal area was contaminated. Sealing bar settings were not correct (pressure/temperature/dwell time).

Wrinkle Description Cause Material fold on one seal surface, caused when one seal surface is longer than the other. Can also be a severe fold over both seal surfaces at sealing time. Cause Sealing surfaces were not flat and parallel or were not tensioned. Various other irregularities in sealing bar or surfaces.

Pouch Inspection Economics One technology useable for all materials Non-Destructive, Non-Invasive No sample preparation, No special Inks, no added variable costs Replaces costly, low efficiency manual Inspection Reduces/eliminates Incubation Saves product & packages Long term quality tracking Integrates into most pouch sealing machines Real Time Process Control - allows immediate corrective action Increases line efficiency Good return on investment You sleep better at night

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