High-Density Sensor Architecture for Precise Leak Detection
At the core of the innovation is a patent-pending high-density sensor architecture featuring multiple integrated CO₂ gas analysers. This enables LeakSecure not only to detect leaks, but also to localise their position on the package. The non-contact technology detects and localises leaks in real time and is designed for use with different packaging materials, colours, and temperature conditions. Its compact footprint and straightforward integration facilitate installation in existing production lines.
Inspection data is continuously captured and analysed through the BRAIN2 digital platform. This makes it possible to identify recurring defect patterns and potential root causes. The data can then be used to optimise packaging materials, sealing processes, and production parameters. LeakSecure therefore extends package integrity testing into an intelligent tool for process optimisation that goes well beyond conventional quality control.
Industrial Use Significantly Reduces Leak Rates
The performance of LeakSecure was validated during a one-year industrial trial at a French meat products manufacturer. The system operated in a two-shift production environment at a throughput of approximately 45 packages per minute and was used across multiple product references.
During the trial, the leak rate decreased from 4-5 percent to 0.52 percent. This reduced the rate of defective packages by up to approximately 90 percent, bringing it down to around one-eighth of its original level. Based on the customer’s production volume, this corresponds to an estimated reduction of up to approximately 484,000 defective packages per year.
“With LeakSecure, we demonstrate that quality assurance and process optimisation do not have to be contradictory goals. The Silver medal at the International FoodTec Award confirms the technological relevance of our solution for industrial food production,” says Carole Besnard, Product Manager Vision Systems at BIZERBA. “Inline testing enables our customers not only to detect leaks reliably, but also to measurably reduce food waste.”
LeakSecure supports reliable quality assurance and stable production processes. By detecting leaks at an early stage, the system can help reduce defective packages and avoidable food waste while conserving resources.
