Mocon Dansensor LeakMatic II Online MAP Package Integrity Tester

Overview

The Mocon Dansensor LeakMatic II is an industrial-grade, online, non-destructive leak detection system engineered specifically for modified atmosphere packaging (MAP) integrity verification in high-speed food production environments. It operates on the principle of differential pressure-driven CO₂ effusion: when a vacuum is applied to a sealed test chamber containing a MAP package, any breach—regardless of size or location—allows CO₂ from the headspace to migrate into the chamber. An integrated optical CO₂ sensor quantifies the rate and magnitude of this gas transfer with high specificity and repeatability. Unlike tracer-gas or vacuum-decay methods requiring calibration gases or complex setup, the LeakMatic II leverages the intrinsic CO₂ concentration already present in fresh meat, cheese, ready meals, and other MAP products—eliminating consumables and reducing operational overhead. Designed for seamless integration downstream of final packaging—typically after case packing—the system performs fully automated, real-time pass/fail evaluation without compromising line throughput.

Key Features

• Fully automated, inline operation with programmable test sequences for up to 16 distinct product configurations
• Optical CO₂ sensing technology ensures high selectivity, long-term stability, and immunity to humidity or temperature drift
• No preheating required: achieves operational readiness within 20 seconds from standby mode and 60 seconds from cold start
• Real-time relay-based output signaling (System Ready, Test Initiated, Pass, Leak Detected) for direct interface with rejection mechanisms and PLCs
• Touchscreen HMI with intuitive workflow navigation, user-level access control, and audit-ready event logging
• Robust mechanical architecture (450 kg frame, IP54-rated enclosure) optimized for continuous duty in refrigerated or ambient production zones
• Comprehensive 3-year warranty on the CO₂ optical sensor—reflecting its calibrated longevity and factory traceability

Sample Compatibility & Compliance

The LeakMatic II accommodates a broad spectrum of MAP formats—including flexible pouches, thermoformed trays, rigid clamshells, and full shipping cartons—without requiring physical modification or sample preparation. Its three standard configurations (Small, Medium, Large) support packages up to 330 × 610 × 300 mm (L×W×H) with contents, and up to 350 × 610 × 400 mm when empty. The system complies with EU Machinery Directive 2006/42/EC and carries CE marking for safe deployment in harmonized markets. While not certified under ISO 11607 or ASTM F2338 per se (as those standards govern laboratory-scale validation protocols), the LeakMatic II’s performance aligns with the functional requirements of ISO 11607-2:2019 Annex D for process monitoring of seal integrity in sterile and non-sterile barrier systems. Its digital log files—including timestamped test results, pressure profiles, and operator actions—support GLP/GMP documentation practices and are compatible with 21 CFR Part 11-compliant data archiving when interfaced with validated LIMS or MES platforms.

Software & Data Management

The embedded firmware provides deterministic, deterministic cycle control with fixed test durations (12–15 s per unit) and configurable vacuum setpoints (down to 300 mbar absolute). All measurement data—including CO₂ concentration curves, pass/fail status, program ID, timestamp, and operator login—are stored locally on non-volatile memory and exportable via RS232 to external databases or SPC software. The system maintains a rolling log of the last 10,000 tests with automatic overwrite protection for critical failure events. No proprietary cloud service or subscription is required; raw ASCII data streams can be parsed directly by third-party analytics tools. Audit trail functionality records user logins, parameter changes, and system alerts—enabling traceability during internal quality audits or regulatory inspections.

Applications

The LeakMatic II is deployed across primary and secondary packaging lines for chilled and frozen MAP products where shelf-life extension depends critically on barrier integrity. Typical use cases include: post-tray-sealing verification for fresh red meat and poultry; end-of-line carton-level screening for multi-pouch retail packs; in-process validation for automated pick-and-place MAP lines serving meal-kit providers; and periodic line clearance checks following format changeovers. Its ability to detect leaks as small as 50 µm (depending on CO₂ concentration and dwell time) makes it especially valuable for products with short ambient shelf lives (<14 days), where even sub-millimeter channel defects can trigger rapid microbial proliferation or oxidative rancidity. By intercepting defective units before palletization, users reduce customer returns, minimize recall exposure, and reinforce brand trust through demonstrable quality consistency.

FAQ

Does the LeakMatic II require calibration gases or consumables?

No. It uses the native CO₂ in the package headspace as the detection medium—no external tracer gases, filters, or reagents are needed.
Can it detect leaks in aluminum-laminated or metallized pouches?

Yes. Because it measures CO₂ diffusion—not light transmission or helium permeation—it functions independently of package opacity or metallization.
Is integration with existing packaging line controls supported?

Yes. Dual RS232 ports and discrete relay outputs (48 V/1 A) enable direct communication with PLCs, SCADA systems, and pneumatic reject stations.
What is the minimum detectable leak size?

Detection sensitivity is application-dependent, influenced by CO₂ concentration (typically 20–100% v/v), package volume, and test duration. Under standard conditions (80% CO₂, 15 s test), it reliably identifies channels ≥50 µm in diameter.
Is the system validated for pharmaceutical or medical device packaging?

While primarily designed for food-grade MAP, its technical specifications meet foundational requirements for ISO 11607-2 process verification. Formal validation must be performed per user-defined protocols and risk assessments.