Leak detection is essential within Lean Six Sigma process checking. Improvement of the checking system of the packaging production line will optimise the production process. In-line leak detection will thus contribute to efficiency.
Normally testing for leaks is carried out manually in the form of random sample testing. With atmospheric packaging this can be done a few minutes after sealing. Vacuum packed items can only be tested after waiting hours or days. If leaking packaging is finally discovered, this disrupts the production process in a major way. The production department must find out how serious the problem is and what caused the leak. Sometimes the machine will have to be shut down, many more packages tested and when necessary repackaging will need to be carried out. This is always tiresome and disturbs production, in some cases with serious consequences. Often this is the reason why production or QC-managers call Oxipack. But prevention is better than cure.
Full steam ahead
Packaging machines work best at full speed. The fewer the stops the better. When starting up the machine runs more slowly and this causes problems. If the sealing process is too slow this can mean the seal is not perfect. Every time the machine stops, for example when changing the foil or due to a leak, new leaks will occur when restarting. Operators know this and immediately walk to the end of the production line to remove the leaking packages. In this way they try to overcome this problem. Automatic leak detection guarantees all leaking packaging will be removed during the start up phase.
Pay back time
How long does it take to recoup the investment? The answer depends on another question: what does leaking packaging cost the company?
Is this difficult to find out? Just ask yourself this:
- What does it cost if a production run of 12 hours has leaks?
- And what is the cost of four hours production for repackaging?
It can sometimes be hard to present a business case if you do not have the exact figures relating to down-time or leak percentages. We can help you with the calculations. The investment in stand alone leak detection can be recouped in a few months. In-line leak detection equipment pays for itself in one to two years. With 100% leak detection the production process becomes more efficient and costs are reduced whilst quality improves. The sooner the operator is aware that something is wrong the better.
Savings achieved through leak detection
Leak detection is a tool that results in savings. Leaking packaging always causes losses in the whole production chain. Leaks also damage your brand reputation.
Savings of one to two tonnes in euro’s for each packaging line per year are possible in the food products sector. The calculations vary according to circumstances and depend on the product and raw materials used.
Calculating the savings
The following factors play a role:
- the costs of the current percentage of leaking packaging;
- cost of the current manual checking for leaks;
- removal of the products that are still usable from the leaking packaging;
- disposal of all spoiled products and packaging;
- temporary storage room if the machines have to be stopped to check which batches are fine and which are leaking;
- costs of repackaging;
- packaging that is only found to have leaked when it is in the shop and has to be reimbursed;
- costs of sending replacement products to clients who have complained;
- damage to the brand or the company’s reputation due to complaints about spoiled or damaged food products.
Is the current packaging destructively tested for leaks? If so the savings are even greater.
Process control
With automatic leak detection the operators immediately notice if something is wrong. The Oxipack in-line leak detection system tests all packaging or a fixed percentage or a set number, for example one in sixty or one in a hundred and twenty. All packaging that appears to have a leak is removed from the production line. Even packages with leaks that are so small that they would otherwise only be noticed after 24 hours are detected and removed. If the number of leaking packages exceeds ten items for example, then a warning is given. Alternatively the packaging machine can be stopped, depending on the preference of the manufacturer. The operator can then investigate why the packaging machine is not working properly. As the operator gains more control over the machine, there will be less leaking packaging. After a few weeks this will gradually result in less stoppages. When the fully automatic leak detection system finds no leaks, the packaging machine will run far more efficiently. This contributes to the Lean Six Sigma programme.
100% output
With in-line leak detection the process becomes more manageable. In-line leak detection increases output and efficiency and disrupts the packaging process as little as possible. Checking for leaks and taking the necessary action, ultimately ensures that the packaging machine runs so efficiently that no more leaking packages are found: 100% output.
