ExtraSolution CarboPack BT Carbon Dioxide Permeability Tester

Overview

The ExtraSolution CarboPack BT is a dedicated carbon dioxide permeability tester engineered for high-precision, time-resolved quantification of CO₂ transmission rate (CO₂TR) through rigid and semi-rigid packaging materials. It operates on the principle of non-dispersive infrared (NDIR) gas sensing, utilizing a dual-wavelength optical subsystem to isolate CO₂-specific absorbance signals while actively compensating for background interference from water vapor and other atmospheric constituents. Unlike gravimetric or manometric methods requiring days to weeks for equilibrium detection, the CarboPack BT delivers statistically robust CO₂TR values in under one hour—enabling rapid iterative evaluation of barrier performance during material development, coating optimization, or production line QC. Its architecture integrates real-time pressure regulation, isothermal chamber control, and active humidity conditioning (optional), allowing users to replicate end-use environmental conditions—including elevated relative humidity (up to 90% RH) and thermal gradients—that critically influence CO₂ diffusion kinetics in polymers such as PET, PEN, EVOH laminates, and aluminum-coated substrates.

Key Features

• NDIR-based CO₂ detection with dual-wavelength compensation for enhanced selectivity and long-term signal stability
• Integrated heating/cooling system enabling controlled temperature testing from ambient to +60 °C, supporting Arrhenius-based activation energy analysis
• Optional humidity-controlled test mode (0–90% RH) to assess hygroscopic effects on CO₂ solubility and diffusivity in barrier layers
• Non-destructive, sealed-cell measurement protocol—preserves sample integrity for post-test physical or chemical characterization
• Automated pressure compensation algorithm that corrects for minor chamber leaks and barometric drift without manual recalibration
• Dedicated electronics board optimized for low-noise analog signal acquisition and microvolt-level baseline stabilization
• Compliance-ready architecture supporting audit trails, user access levels, and electronic signature functionality aligned with GLP/GMP documentation requirements

Sample Compatibility & Compliance

The CarboPack BT accommodates standard flat films (ASTM D3985 format), preformed containers (e.g., PET bottles, glass closures, aluminum screw caps), and closure systems including natural and synthetic corks. Its modular test cell design supports both symmetrical and asymmetrical diffusion configurations—critical for evaluating heterogeneous structures like multilayer coextrusions or metallized coatings. The instrument meets functional equivalency benchmarks referenced in ISO 15105-2 (plastics—determination of gas transmission rate—part 2: CO₂), ASTM F2622 (standard test method for CO₂ permeability of plastic film), and supports data traceability required under EU Regulation (EC) No. 1935/2004 for food contact materials. All firmware and software modules are validated per ICH Q9 and aligned with FDA 21 CFR Part 11 expectations for electronic records and signatures.

Software & Data Management

Control and analysis are executed via CarboPack Studio—a Windows-based application offering real-time sensor diagnostics, multi-parameter trending (CO₂ flux vs. time, temperature, RH), and automated calculation of permeability coefficient (P), diffusion coefficient (D), and solubility coefficient (S) using Fickian modeling frameworks. Raw data files are stored in vendor-neutral CSV and XML formats; metadata embedding includes operator ID, calibration timestamp, environmental setpoints, and instrument serial number. Audit trail logs record all parameter modifications, test start/stop events, and calibration actions with immutable timestamps. Export modules support direct integration into LIMS platforms via ODBC and generate PDF reports compliant with internal SOP templates or external regulatory submissions.

Applications

• Accelerated shelf-life prediction for carbonated beverages by correlating CO₂TR with headspace pressure loss over storage time
• Evaluation of barrier coating efficacy (e.g., SiOₓ, AlOₓ, PVDC) on PET preforms under humidified conditions
• Comparative assessment of natural vs. agglomerated cork stoppers for sparkling wine applications
• Thermal stability profiling of EVOH-containing laminates across refrigerated to ambient distribution temperatures
• Leak detection at sub-micron defect levels—identifying weld seam failures, micro-cracks, or seal delamination invisible to dye penetration tests
• Supporting migration modeling under EFSA and FDA food contact substance notification (FCN) dossiers

FAQ

Does the CarboPack BT require carrier gas or consumables?**
No—operation is self-contained using ambient air as reference; no zero gas, span gas, or replaceable optical filters are required.
Can it measure O₂ or H₂O vapor transmission simultaneously?**
No—it is purpose-built exclusively for CO₂TR; separate instrumentation is recommended for orthogonal barrier metrics.
Is third-party calibration certification available?**
Yes—NIST-traceable calibration services are offered annually, including uncertainty budget documentation per ISO/IEC 17025.
What sample preparation standards apply?**
Samples must be cut to ASTM D3985 dimensions (100 mm × 100 mm) for flat films; container testing follows ISO 15105-2 Annex B guidelines for geometric normalization.
How is leakage distinguished from true permeation?**
The system applies transient-state analysis: permeation yields exponential asymptotic curves, whereas gross leaks produce linear or stepwise CO₂ accumulation—automatically classified by built-in pattern recognition algorithms.