Founded with the mission to make healthy snacking exciting and convenient, Graze has successfully transitioned from a ground-breaking snack-box subscription service into a major international retail brand. Based out of London, UK, Graze specializes in portion-controlled, wholesome snacks that range from nuts and seeds to their signature wholesome flapjacks. As a premium brand dedicated to excellence, maintaining absolute product freshness and a flawless customer experience is central to their daily operations.DOWNLOAD PDF
Graze implements SealScope® for in-line seal inspection of pouches with crunchy snacks
The quality challenge: Automation beyond manual inspection
As Graze scaled its production by automating on a high-speed pouch forming packaging line, the operational team faced the critical challenge of ensuring perfect seal integrity at maximum throughput. Historically, quality control at the facility relied heavily on manual inspection and batch testing while the team wanted to move to the highest possible automated quality control.
To support their automated end-of-line packaging goals and reduce the risk of batch re-testing, Graze required an automated, 100% in-line inspection solution capable of checking every single pouch in real time.
The search for the in-line pouch inspection technology
When Project Manager Khoshal Mann set out to evaluate automated seal inspection options, the selection criteria were clear. Having originally encountered Engilico’s technology years prior at a PPMA trade show, the project team conducted extensive market research to evaluate various inspection methods against their specific factory constraints.
Graze initially evaluated three primary inspection methods to solve their sealing challenge. Standard vision inspection systems were considered but quickly proved ineffective at reliably detecting hidden contaminants or wrinkles inside the complex, flexible film layer of the pouches. The team also looked into gas detection, often referred to as sniffing systems. While technically capable, sniffing systems require a significant amount of physical space on the factory floor. Because Graze’s manufacturing facility is located near London, where industrial real estate prices per square meter are expensive, modifying the existing line layout to fit a bulky external system was economically and structurally unfeasible. Engilico’s patented, in-machine SealScope® emerged as the ideal choice because it integrates directly into the existing packaging machinery, requiring zero modifications to the footprint of the production line and preserving valuable factory floor space.
Crucial decision factors
Two primary factors solidified Graze’s decision to partner with Engilico for this critical upgrade. First, Engilico organized a direct meeting between Graze and an independent, long-time SealScope® customer who was already packaging pouches on a similar packaging machine. This peer testimony provided transparent, positive feedback regarding the long-term performance of the system and allowed the Graze team to get direct answers to their specific operational questions. Second, Graze required a fast turn-around solution to keep pace with immediate production demands, and Engilico responded with exceptional agility, managing the entire project turnaround from initial alignment to final delivery in less than six weeks.
In-line seal inspection operation
Unlike destructive testing methods or external cameras, SealScope® utilizes highly accurate mechanical sensors integrated directly onto the sealing bar holders of the pouch packaging machine. Every single time a pouch is sealed, the system instantly compares the real-time seal profile data against a reference baseline seal that is automatically and adaptively defined at every start of and during production. If a small product contamination, like a tiny seed, or a wrinkle compromises the seal area, the system detects the variation immediately. The defective package is automatically flagged and rejected down the line without interrupting or slowing down the continuous, high-speed production flow.
Efficient implementation
The installation process at the London facility was fast and efficient, supported by comprehensive training delivered on-site by Engilico’s engineering team. The system quickly proved its diagnostic value through its advanced monitoring function. On one occasion during production, the SealScope® system started rejecting an unusually high volume of pouches. The user definable process alarm halted the packaging process and instead of an isolated product-in-seal issue, the review of the packaging machine revealed that a mechanical component within the sealing jaws was loosening. Thanks to the immediate alarm mechanism, SealScope® helped the team catch and resolve a mechanical issue before it could affect product quality.
Ready for the future
Having realized the tangible value, reliability, and space-saving design of Engilico’s technology, Graze now operates with complete confidence in their pouch sealing integrity. Graze fully recognizes the long-term value of SealScope® as a core asset for automated quality control. With multiple packaging lines running across their operations, the company is expected to consider the technology for further implementations across their future expansion projects.