How to inspect the leakage problem of spouted pouches?

In the previous article, I discussed the challenge of controlling the leakage percentage of spout pouch with cap to below 0.3%. I emphasized that relying solely on the experience of machine operators is insufficient; additional testing methods and equipment are necessary to achieve this goal. In this essay, I will delve into the methods and equipment required for effective leakage control in spout pouch production.

Traditional leakage testing methods are commonly used during the debugging and batch production phases of pouch making. The primary objective of this method is to identify any leakage issues when the spouted pouches are subjected to external forces. During the initial phase of pouch making, machine operators are required to continuously adjust and debug the machine to achieve the optimal pouch shape and edge sealing. This involves conducting a high frequency of sampling inspections, typically examining every 5 pouches. If the results of the sampling inspection are satisfactory, the production process can be accelerated, while still maintaining the same frequency of sampling inspection. As the production speed increases, the frequency of sampling inspection is gradually reduced, eventually settling at once per 100 pouches.

Leakage testing equipment is essential for the debugging and batch production phases of spout sealing. This equipment is designed to detect any leakage issues that may arise when the spouted pouches are not subjected to external forces. Similar to the traditional leakage testing method, the process involves continuous debugging and adjustments to achieve the most suitable temperature for spout sealing. The frequency of sampling inspection is initially high, with inspections conducted for every 5 pouches. As the process stabilizes, the frequency of sampling inspection is reduced in a similar manner to the traditional leakage testing method.

In addition to traditional methods and equipment, it is crucial to employ testing methods that simulate the conditions of a pasteurizer tunnel for spouted pouches that require pasteurization. This involves creating a virtual environment with a temperature range of 80 to 90 degrees to assess any potential leakage problems. The frequency of sampling inspection for this method is lower compared to the traditional methods, with inspections conducted once per 100 pouches during the debugging phase and once per 500 pouches during the batch production phase.

Adhering strictly to the above processes is essential for controlling the leakage percentage below 0.3%. However, it is important to note that this rigorous approach may result in a high pouch loss rate, estimated at 5-10% for standard spout pouches and 10-15% for shaped spout pouches. Manufacturers should be prepared to cover these losses, ensuring the quality and integrity of the spout pouches supplied to customers.

In conclusion, the combination of traditional leakage testing methods, specialized equipment, and simulation of pasteurization conditions is essential for effective leakage control in spout pouch production. By implementing these methods and equipment,spout pouch suppliers can ensure the highest quality and reliability of their products, meeting the stringent requirements of the industry.