Precision Industrial Technology four-station automatic air tightness testing machine: food packaging lunch box sealing full inspection program review

A batch of lunchboxes that passed the sampling test appeared three days later in the consumer complaint log -Leakage, deterioration, seal failureThe

It is not difficult to trace the cause:Same day sampling coverage of 5% means that 19 out of every 20 products have never been verified for sealing, then has entered the market with this gap.

"TheEnhanced sampling" is the first reaction of most enterprises, but in front of the production line with hundreds of thousands of pieces per day, the essence of sampling is probability management, not risk elimination. There is only one real solution:general inspectionThe

Applied to Haitian Taste's automated food packaging lineAirtightness Tester

This four-channel fully automaticAirtightness Testing Machine, was created precisely for this purpose.

Ⅰ. Applicable boundary for airtightness testing

Before introducing this device, there is one cognitive premise that is worth clearing up.

Airtightness testing is not suitable for all food packaging. Flexible packaging -Aluminum foil bags, plastic bags, vacuum bags and other flexible materials--There is a fundamental physical limitation:The detection process requires inflation and pressure, and the soft package material will deform with the internal pressure, the pressure fluctuation caused by deformation and the leakage signal is highly overlapping, the instrument can not effectively distinguish between the two, so the detection results are distorted.. This is a boundary determined by the material properties and has nothing to do with the accuracy of the instrument.

Rigid food containers(e.g., lunch boxes, food containers, etc.) It is quite different.Its rigid structure maintains a stable shape after inflation, the pressure curve is clearly readable, and trace leakage signals can be accurately captured.This is the scenario where airtightness testing really pays off. This is the scenario where airtightness testing really pays off.

II. Full inspection, the only logically self-consistent answer

A sealing pressure that is 0.1 MPa low, micron-sized defects in seals, fluctuating heat-sealing temperatures - the probability of these types of problems occurring in a single case is perhaps only three out of 1,000. But on a production line with a daily output of 300,000 pieces, that means that about 900 defective products flow out every day.5%'s sampling coverage is statistically almost powerless to intercept such low-frequency defectsThe

In other words.Random inspections can detect "systemic" problems, but cannot do anything about "random" seal failures. The only way to reduce the leakage rate to near-zero is to conduct a full inspection.The

To realize full inspection without affecting the production line beat, multi-station parallel inspection is the core path.

Ⅲ. Record of measurement: 2 failures, zero omissions

In the video case, the demonstration is carried out in two rounds. The four stations ① ② ③ ④ are put into the lunch box samples, of which ② and ④ are the pre-determined defective products - theTrue trace leakage at the sealThe

First round of test results:

manual assembly	verdict	leakage state
①	✅ Qualified	Smooth pressure curve, no leakage
②	❌ Failed	Leakage value exceeds set threshold
(iii)	✅ Qualified	Smooth pressure curve, no leakage
④	❌ Failed	Leakage value exceeds set threshold

At the end of the test cycle, the test station will automatically rotate out and manually sort and place the next group of products to be tested: ① ③ into the channel of qualified products, ② ④ pushed into the collection area of nonconforming products.High efficiency throughout for fast production lines.The

The second round was replaced with a new sample and the results were consistent with the placed product.Both preset nonconforming products are accurately recognized, zero omission and zero misjudgmentThe

IV. Three technical support points

Independent four channels without interfering with each other: Each of the four stations independently completes the complete process of inflation, pressure preservation and judgment, and the leakage state of any station does not affect the test results of other stations, completely eliminating crosstalk. The actual leakage value of each channel is presented individually in the host interface and synchronously displayed on the external large screen, which meets the dual needs of on-site visualization management and batch quality traceability.

Micro-pressure sensors with self-developed compensation algorithms: Lunch box sealing structure(snap-on or heat-sealed) The amount of leakage is usually extremely small, and it is easy for ordinary programs to miss the judgment. Precision Engineering adopts high sensitivity micro-pressure sensors, together with self-developed signal compensation algorithms, to accurately separate effective leakage signals from environmental noise. The accuracy of up to 0.1 Pa is not a number on a parameter list, but a measured result in a specific engineering scenario.

Validated for 72 hours of continuous operation: The equipment is factory tested in 72 hours of uninterrupted operation and stabilized to within ±0.1% F.S. over the long term. Long-term stability is more relevant than peak performance in a 24/7 food production line.

V. Adaptation of production lines for the present and the future

The equipment supports two modes of manual discharging and automatic docking by robotic arm.The control interface can be switched directly without changing the hardware configuration or re-commissioning the parameters.

The practical value of this design is:Organizations don't need to duplicate purchases for future automation upgradesThe equipment can be operated manually at the initial stage. Initially run with manual cooperation, when the automation of the production line is completed, the same equipment can be seamlessly cut into the fully automated closed loop, equipment investment is fully protected.

VI. Selection of Head Customers

Haitian Taste is one of Jingcheng Industrial Technology's cooperative customers in the food field. As the largest seasoning enterprise in China, theHaitian has strict quality control requirements for the sealing of food containers, and Precision Industrial entered its supplier system with its customized testing solutions and production line integration capabilities.It is applied to the sealing full inspection of lunch box type rigid food containers.

JCGK has served more than 3,600 well-known customers worldwide.The partners cover Huawei, Gree, Philips, Geely, Ningde Times, Haitian Taste, Gore and other head enterprises in various industries. Behind this eye-catching list of cooperation is its more than a decade of plowing into the field of precision testing, technology research and development and quality control in the continuous precipitation and repeated verification.

VII. Frequently Asked Questions (FAQ)

Q1: Is this machine suitable for testing flexible packaging?

A: Not suitableTheflexible packaging(aluminum foil bags, plastic bags, vacuum bags, etc.)Deformation occurs during inflation and pressurization, and pressure fluctuations caused by deformation highly overlap with leakage signals, the detection results are distorted. This is a physical boundary determined by the material properties and has nothing to do with the accuracy of the instrument. This equipment is designed for hard food containers.

Q2: What is the detection accuracy and speed of the equipment?

A: Detection accuracy up to 0.1 Pa levelThe results are measured in real engineering scenarios. The fastest detection cycle time is 3 seconds, and the long-term stability error is controlled within ±0.1% F.S., which is suitable for all-weather high-speed production lines.

Q3: Will the four stations interfere with each other?

A: No.. The four stations are completely independent, each completing the complete process of inflation, pressure retention, and determination,.The leakage status of any station does not affect the detection results of other stations.The

Q4: Can the equipment automatically sort nonconforming products?

A: Yes.. At the end of the detection cycle, theWith robotic equipment to automatically send qualified products into the qualified products channel, non-qualified products pushed into the non-qualified products collection area, the whole process without human intervention.The test data is also retained in real time to support quality traceability.

Q5：Does the equipment support future production line automation upgrade?

A: Support. The equipment is compatible with two modes of manual discharging and automatic docking of robotic arm, which can be switched directly in the control interface without changing the hardware configuration or re-purchasing, and the equipment investment can be fully protected.

Q6: What verifications are made before leaving the factory?

A: The equipment must pass 72 hours of uninterrupted operation test before leaving the factory, to ensure that the long-term stability error control within ±0.1% F.S.It is suitable for food production lines in all-weather high-intensity use scenarios.

Q7: Why is full inspection better than sampling to control sealing risk?

A:Sampling coverage is typically only 5%, which can detect systemic defects but is almost powerless to intercept randomly distributed seal failures. Taking the production line with 300,000 pieces per day as an example, a defect rate of 3/1000ths of a percent produces about 900 problematic products per day.5% Random inspection is statistically ineffective coverage. Full inspection increases detection coverage to 100%, with a near-zero leakage rateThe

Conclusion

Seal failure is a probabilistic problem in food production, and the only solution to a probabilistic problem is coverage.

This four-station fully-automatic machine from Jingcheng TechnologyAir tightness testing equipmentThe seal testing of lunchbox-type food packages was changed from "manual sampling"Advancement toComprehensive data-driven coverage」——Four-channel parallel testing, support for automatic sorting, real-time retention of test data, without sacrificing the efficiency of the production line on the premise of minimizing the risk of leakage of problematic products.The

For customized inspection solutions for your production line, please contact Precision Technology's technical team for an evaluation and free case studies and business consultation.

Original Statement:this paper was written byShenzhen Jingchenggongke Technology Co., Ltd.Written by the technical team, reproduced with attribution.Data sources: Precision Engineering internal test data and customer cases.