Join us for a free webinar that explains:

• Why in-line seal inspection is a must in food packaging
• Basics of SealScope® for 100% seal inspection of flexible packaging
• Case stories on how our customers use inline seal inspection
  • For various food applications: Meat, cheese, pet food, fresh produce, powder
  • Using different package types: Pouches, (VFFS) Bags, Flow wraps
  • On multiple machines brands: PACRAFT (Toyo Jidoki), FUJI, OMORI , ILAPAK, HDG , etc.

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The post SealScope update webinar: Use cases of in-line, 100% seal inspection ​​​​​​​to improve packaging quality and productivity appeared first on Engilico.

At IFFA 2025 (May 3-8, Frankfurt), Engilico introduces an in-machine version of the HyperScope® seal inspection system. This system utilizes hyperspectral imaging to accurately detect seal contamination in plastic or cardboard trays and thermoforms. Mounted above the packaging line, in-machine seal inspection offers numerous advantages, including eliminating the need for additional space in the packaging line, eliminating the need for extra conveyors, and promptly identifying defective packages immediately after sealing, when packages are still ideally shaped and positioned.

HyperScope® uses hyperspectral imaging (HSI) and artificial intelligence image processing technology to reliably and swiftly detect contamination in the seal of trays, with a much higher contrast than standard vision cameras. As hyperspectral cameras capture information of material composition, rather than only RGB colours, these are perfectly suited for in-machine seal inspection. Even when using opaque or printed plastic foils, colored or cardboard thermoforms – when contamination is hardly or not visible for traditional vision-based systems – seal contamination can be detected by a hyperspectral camera.

HyperScope’s camera and illumination are both positioned above the processing line, before the packages are cut and separated.  Inspecting the packages right after the sealing phase is also the ideal moment, particularly when handling thinner or more flexible film, as the packages are still undeformed and stable positioned when transported under the camera.

The AI-powered hyperspectral solution delivers automatic and precise seal identification and reliably detects contamination in the sealing area of the product. Another benefit is that the in-machine solution can also handle arrays of products in one single processing step.

Defective packages are subsequently removed from the packaging line by e.g. an ejector or pick & place robot system. This has an immediate positive effect on outgoing product quality, line efficiency and total cost, with less rework and avoided recalls. Typical applications are in-line seal inspection of trays or thermoforms with meat, meat substitutes (vegetarian proteins), fish, cheese, ready meals, etc.

In-line, 100% seal inspection for flexible packages
Beside seal inspection of rigid packages, Engilico also showcases SealScope® for in-line, 100% seal inspection of flexible packages. SealScope® is an easy-to-integrate and non-destructive in-line seal inspection and process monitoring technology for popular packages such as pouches, VFFS bags, flow wrappers, etc. For meat applications, SealScope is ideally suited for seal inspection of sausages, meat balls, bacon, sliced meat where flow-pack, pouches or VFFS packaging types are used or when replacing trays or thermoforms to reduce plastic waste.
SealScope® integrates with major machine brands such as PACRAFT (previously Toyo Jidoki), SN Packaging, Leepack, HDG, Fuji Packaging, Omori, ULMA, Ilapak, PFM, GEA, Rovema, Volpak, Mespack, and many more.

More info
Engilico@IFFA  (Frankfurt, Germany), Hall 12.0 A28
Contact Renaat Van Cauter | renaat.vancauter@engilico.com

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Tirolpack GmbH is a state-of-the-art cheese cutting and packaging facility located in the heart of Tyrol and has been part of the Pinzgau Milch group since 2022. As a co-packer, they specialize in cutting, slicing and packaging hard and semi-hard cheeses for retail and the food industry. Tirolpack processes regional natural products under the premise of best quality, requiring high demands on technology, automation and employees. In line with their quality philosophy, Tirolpack deployed a SealScope® in-line seal inspection system for their flow-pack packaging line of cheese wedges.

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Tirolpack started operation in 2018 in Schlitters with the vision of having local cheese specialties packaged independently and regionally. Today, Tirolpack GmbH is one of Europe’s most modern packaging companies, with continuous investments in maintenance and modernization to ensure a consistently high level of innovation. As the company’s vision implies “Standstill is regression”, embracing the latest technology is essential to their success.

Success through quality

To ensure high quality standards, all production processes are fully monitored and documented by a comprehensive quality assurance system. The company meets the rigorous standards of IFS, along with various other industry certifications, allowing them to proudly label products with the respective quality seals.
Tirolpack operates several production lines that process cheese blocks and round loaves in a variety of sizes. In addition to traditional cut and sliced formats, the company’s advanced equipment also produces wedge-shaped pieces.
Particularly for the line where cheese with a crust of alp herbs is packaged, Tirolpack retrofitted the ULMA flow-pack line with an in-line seal inspection and monitoring system to guarantee the best seal quality.

Seal inspection for flow-packs

In fresh food packaging, such as cheese, maintaining a protective atmosphere is essential to preserving shelf life. Quality control of the seals is therefore critical to prevent leaks or open packages. This is especially true in fully automated end-of-line production, where instant, in-line seal inspection is crucial.
“Before implementing the solution, Tirolpack consulted several Engilico references in Austria to assess the capabilities of SealScope®.”, explains David Berger, Plant Manager at Tirolpack.
The innovative SealScope® system uses retrofitted sensors on the sealing bars to detect defects in the seal, such as folds, cheese, or in this case, herbs, which could lead to leaks or open packages. The system validates the seals during the sealing process, and when faults are detected, the affected cheese packages are automatically ejected from the conveyor belt by an air-blast system. These rejected products are then inspected to determine if they can be repackaged, ensuring minimal waste.” An important advantage is that SealScope® can be integrated onto most heat-sealing packaging machines, independent of machine brand.

Monitoring the packaging process
Another key feature of the SealScope® system is its ability to monitor the entire packaging process. The system collects real-time production data for each product variety, tracking metrics like the number of good versus rejected packages. By inspecting every package individually, it can identify trends, such as increasing rejection rates or deviations in seal quality, that may indicate potential issues in the packaging line. If a rising rejection rate is detected, the system can automatically pause production, allowing for proactive maintenance or adjustments to be made before the defect ratio further increases. This helps preventing the production of faulty packages and minimizes delays.
In the unlikely event support is needed, Tirolpack can rely on remote assistance through TeamViewer, allowing engineers at Engilico’s headquarters to access and control the SealScope® system. This enables fast troubleshooting and interaction, avoiding the need for costly and time-consuming on-site support visits.

Sustainability as a guiding principle
Since food, and particularly cheese, is a valuable resource, Tirolpack is committed to sustainable business practices preserving resources and the environment. In-line seal inspection during production fits in this philosophy as the amount of possible leaking packages is strongly reduced. Furthermore, rejected packages with defective seals can often be repackaged, also reducing waste. The monitoring function warns operators or can even halt production in case of increasing rejects, avoiding waste of packaging film and the need for manual verification and sorting.
“We are very satisfied with the SealScope® system”, concludes Mr. Berger, “This is a true value-adding inspection technology as it not only improves outgoing quality, but also monitors the complete packaging line. We are definitely evaluating to equip more of our packaging lines with this innovative in-line seal inspection technology.”
Continuous investments are planned for the future to maintain our advanced standards, and these efforts will also contribute to the creation of new jobs in the region.

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Food packaging for supermarkets and retail stores requires a careful balance between ensuring product freshness and quality, using eco-friendly materials to reduce waste, and creating appealing branding to attract customers – all while keeping costs optimal and efficient. While some large supermarkets have their own food processing and packaging facilities, many products are provided by independent food factories or co-packers. A crucial aspect is the packaging quality, as defects can result in product spills, health risks, brand damage, and costly returns or recalls.

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With the increasing demand for high production volumes, it’s essential for food factories to implement automated packaging and inspection processes to prevent defective packages from reaching supermarket shelves. Although standard inspection steps like label inspection, metal detection and check-weighing are common, automated in-line seal inspection is particularly beneficial, as sealing is a critical step in packaging process. The use of new recyclable materials to reduce waste carries a risk of defective packaging, as the seal quality might not yet match the consistency of traditional materials that have been used for decades. 100% in-line seal inspection not only ensures product quality and shelf life but also enhances packaging processes and productivity, ultimately lowering costs for both food producers and supermarkets. This is why supermarkets have strong incentives to require their suppliers to implement seal inspection in their packaging processes. Also, in-line seal inspection itself represents a minor investment compared to the cost of an entire packaging line.

Packaging formats and trends
Maintaining the quality of food products is essential for preserving their freshness, taste, and visual appeal. Various flexible and rigid packaging formats are used depending on the application, often packaged under modified atmosphere conditions to prevent product degradation due to oxidation. Below is a brief overview of some of the most commonly used packaging formats:
• Flow-packs for sliced cheese, charcuterie, sausages, minced meats, tortillas, pizza dough, cookies, etc.
• VFFS bags for fresh cut, grated cheese, frozen food, cereals, chips, etc.
• HFFS/Pre-made pouches for ready meals, soups, cheese/meat chunks, cereals, pet food, etc.
• Trays/Thermoforms for meat (bacon chunks, sliced meat), sliced cheese, ready meals, appetizers, etc.
In the 2010s, resealability emerged as an innovation across these packaging formats, providing convenience for users, though it offered limited improvement in conservation once the package was opened and exposed to air.
More recently, the focus has shifted to the use of recyclable materials, such as paper-based or mono-material packaging, and reducing the amount of plastic used. This reduction is often achieved by changing the packaging type (e.g., switching from trays to flow-packs or using thinner films or trays). Another growing trend is the shift from cans and jars to pouches. However, regardless of the packaging format, ensuring a secure seal is crucial for maintaining freshness and product quality.

Packaging challenges and social media impact
In assessing customer appeal and product attractiveness, packaging branding plays a crucial role. Elements like printed films or colored trays can evoke a sense of quality and luxury, which are often key factors for discerning customers. However, these printed films can also introduce packaging challenges, which will be explored further. In today’s digital landscape, social media plays a significant role for supermarkets. Influencers, marketing campaigns, and storytelling (such as sharing recipes) are commonly used to promote products. At the same time, social media provides an easy platform for customers to voice their dissatisfaction with just a few clicks, particularly regarding product quality. When photos of defective products go viral, the resulting brand damage can be substantial.

Ensuring quality and safety
To minimize the risk of defective packages, it is crucial to implement stringent quality control measures. Supermarkets often conduct sample-based incoming quality control and regular audits of their suppliers, examining production processes, inspection technologies, and final outputs. By collaborating closely with suppliers, supermarkets can enforce the adoption of specific production and inspection technologies, thereby enhancing overall quality and meeting their rigorous standards.
Given the high production and packaging speeds in the food industry, particularly for high-volume products, it is essential to implement automated packaging lines that include inspection and rejection of defective packages. Automation is increasingly necessary as finding and retaining skilled operators becomes more challenging, and human errors and distractions can compromise quality. Automated systems can efficiently handle repetitive tasks, ensuring consistent performance.
Compliance with stringent food safety regulations is mandatory for all food manufacturers and packaging facilities. Inspection steps like metal detection, check-weighing, and label inspection are widely accepted and standardized to meet these regulatory requirements. While these inspections focus primarily on safety and information, they are less effective in ensuring overall package quality. Seal inspection, however, is a critical step in maintaining packaging quality. Often, this inspection is limited to sample-based testing methods, such as submerging samples in a bath or using a leak-testing device every 15 minutes. If a defect is found in a sample, a portion of the production batch typically undergoes further inspection—a labor-intensive and disruptive process.
A more efficient approach involves checking every package during the packaging process and rejecting defective ones before they are sealed and palletized. This method enhances quality control, reduces labor costs, and minimizes the likelihood that poorly sealed packages will reach the market.

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The post Application Case: ALSO SUPERMARKETS BENEFIT FROM SEAL INSPECTION OF FOOD PACKAGING appeared first on Engilico.

Engilico announces the appointment of Koen Muylkens as its new Managing Director, succeeding Olivier Georis, one of the original founders of the company established in 2011.

Koen Muylkens brings a wealth of experience in leadership and techno-commercial roles within the engineering, software and telecommunications sectors.

Mr. Kitamura-san, President at PACRAFT Japan, expressed his confidence in Koen’s appointment, stating, “With his entrepreneurial spirit and strong engineering background, I am convinced that Koen Muylkens is the perfect fit to lead the Belgian-based Engilico entity.”

Koen Muylkens commented, “I’m fascinated by the innovative inspection solutions offered by Engilico. I am eager to further develop and market next-generation packaging solutions alongside these multi-talented (engineering) teams in Leuven, Japan, and other countries.”

For more information about Engilico and its innovative seal inspection solutions, please visit www.engilico.com .

Contact Information:
Renaat Van Cauter: Renaat.vancauter@engilico.com | +32 16 498 139
Engilico: www.engilico.com
PACRAFT: www.pacraft-global.com
Koen Muylkens LinkedIN

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Schwarzwaldhof implements hyperspectral seal inspection for better packaging quality of bacon chunk trays
The Black Forest ham, sausage and bacon specialties from Schwarzwaldhof are always a delight. Schwarzwaldhof knows what makes these specialties so unique: the best ingredients, the experience of their employees combined with modern technology. And the latest addition to the extensive quality controls is a vision-based hyperspectral seal inspection system to detect bacon trays with product in the seal to avoid leaking packages.
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The history of the production plant in Blumberg began in 1965 and since then, the site has been progressively extended to provide new product variations and increased production capacity. As a subsidiary of EDEKA Südwest, the Blumberg-based factory has been a guarantee for excellent regional products, that are available in over 1.000 EDEKA stores. Today, Schwarzwaldhof employs around 330 highly qualified people who ensure the highest quality of the Schwarzwaldhof products.

Packaging a variety of bacon products

Beside the Black Forest sliced ham and sausages, an important product assortment are bacon chunks that are packaged in many variations and tray formats: single and duo trays, ultra-fine slices or larger chunks, originating from various types of meat, for different retail customers: all resulting in more than a dozen product variations.
The bacon is packaged on a MULTIVAC tray processing line, where the trays are filled and sealed under modified atmosphere conditions to preserve the freshness of the product.
Until mid-2023, the different inspection steps were X-ray, metal detection, weight control and finally before placing in carton boxes, a visual inspection was also done by the operators. The X-ray was initially intended to detect seal contamination: as the bacon products are gassed, seal inspection is crucial to preserve freshness. Compromised, leaking trays with product-in-seal need to be removed from the line and can at no cost leave the production site. At a production rate of up to 120 trays per minute, this end-of-line packaging was performed by up to 5 operators, a challenging and stressful task.
Schwarzwaldhof decided to optimize the end-of line packaging and had two goals: install an automated tray stacker to reduce the number of packaging operators and secondly systematize the efficiency of the seal inspection. The X-ray system, that qualifies foreign bodies based on differences in densities, was not suitable for seal inspection as the small parts of bacon were not reliably detected in the seal. Therefore, in 2022 Schwarzwaldhof started searching for an efficient, in-line seal inspection system that could cope with different – including printed – top seals and eliminate the need for visual inspection by the end-of-line packaging team.

Groundbreaking hyperspectral seal inspection

Schwarzwaldhof was already familiarized with Engilico’s solutions for seal inspection of flexible packaging (flow-packs, bags, pouches) and it was on packaging tradeshow Fachpack that they first saw HyperScope® Engilico’s new hyperspectral seal inspection solution. After successful testing of sample trays, Schwarzwaldhof decided to replace their X-ray system with the hyperspectral seal inspection system. HyperScope® uses hyperspectral imaging to detect seal contamination with obvious contrast, even with printed film. The inspection system features GPU-accelerated artificial intelligence (AI), enabling real-time, high-precision seal area detection. The detected sealing area is analyzed in several post-processing steps to detect e.g. seal breaches, contamination inclusions in the seal, etc. Finally, based on configurable decision criteria the package is accepted or rejected.
Hyperspectral cameras capture information from a large part of the electromagnetic spectrum including infrared wavelengths that penetrate the plastic top films. Hyperspectral imaging, therefore, unlocks new inspection possibilities where classic imaging often falls short, e.g., on printed film packages which are often used in premium products. The system can inspect up to 160 packages per minute, a speed that is well aligned with sliced, chopped and/or bulked-food production lines.
HyperScope® is equipped with its own conveyor belt and an integrated reject unit.
“Seal defects can have a disastrous impact on the conservation of the bacon product.”, says the Packaging Manager at Schwarzwaldhof, “As we were streamlining our end-of-line production, it is very important for us that 100% of our products are inspected.”
Even for aesthetic purposes, product inclusion in the sealing area is not acceptable for retail. HyperScope® can be configured to only reject critical contaminations that breach the seal while smaller, less critical seal inclusions can be optionally ignored. The defective trays are automatically rejected by the
HyperScope® system, collected in a box and re-packaged to avoid any loss of product. “In this way, through early defect recognition, the system also contributes indirectly to our strategy: helping to reduce waste and energy.”

Smooth installation, performant operation
The X-ray system was decommissioned and swiftly replaced by the HyperScope® system. The embedded conveyor was specifically designed to fit in the layout of the production line. The system communicates its operational status to the MULTIVAC thermo-former to synchronize the movement of the conveyor.
“We are very pleased with the installation and support by the Engilico team.”, adds the Packaging Manager, “Also, our operators reported that their overall job satisfaction and focus have improved since the automated, in-line seal inspection system has relieved them of the constant stress and fear of missing errors during visual inspections.”
HyperScope® is capable of processing different product variations, which is important as Schwarzwaldhof is producing for varied brands in several package weights and sizes. In total, more than 12 different product models were created and extensively validated. All daily inspection information for the different products is saved in a database that can be exported in many reporting formats.
An important benefit is the excellent remote support by Engilico’s team. The system UI can be monitored and adapted from within Engilico’s headquarters. As such, data can be captured to further train and finetune AI models, software upgrades or system fine-tuning can be efficiently addressed without wasting valuable time with local support visits.
“We experience less complaints, both internally as externally.”, concludes the Packaging Manager, “HyperScope® is a true innovative and performant inspection solution that is particularly suited for trays, even with printed top film.”
As Schwarzwaldhof has many other tray production lines for sliced ham and bacon, as well as flow-packers for sausages where end-of-line automation is in the picture, they are definitely interested in further implementing Engilico’s seal inspection technologies to globally increase their packaging quality and productivity.

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At the Pack Expo International (Chicago, Nov 3 – 6), Matrix Packaging Machinery (S-3620) demonstrates Engilico’s SealScope® seal inspection solution on a PACRAFT TT-8D-N packaging machine.

Engilico also exhibits its in-line seal inspection solutions at booth N-5733 and on the PACRAFT booth (LU-8547)

SealScope® is an easy-to-integrate and non-destructive in-line seal inspection and process monitoring technology for flexible packages such as pouches, VFFS bags, flow wrappers, etc. The innovative SealScope® system uses sensors mounted on the sealing bars to detect undesired product in the seal or folds, which can lead to open packages. Every produced package is instantly compared to a reference seal and when sealing errors are detected, the defective packages are automatically ejected from the conveyor belt. In addition to inspecting every individual product, SealScope® also monitors the quality of the complete packaging process. By issuing early warning signals when the sealing process is drifting, operators can execute proactive maintenance to avoid unplanned production stops.

At Pack Expo International, SealScope® is demonstrated on a PACRAFT TT-8D-N pre-made pouch, filler/sealer, suited to fill and seal a variety of products at high speeds. But, the in-line seal inspection can also be retrofitted to VFFS baggers, including models such as the Matrix Mercury, HFFS packaging machines from Bartelt and Ossid, or (long dwell/ box-motion) flow wrappers from Reepack.

“As Matrix is the master distributor of the PACRAFT pouch packaging machines and Engilico recently joined the PACRAFT group, it is a logical step to introduce this innovative seal inspection solution at our shows”, says Christine Duncan, Marketing Director, for the ProMach Flexibles and Trays Business Line, “It is a very interesting technology that can help our customers to improve packaging quality and productivity.”

About Engilico
Engilico (Rotselaar, Belgium) delivers innovative technologies to inspect, monitor and optimize the sealing process of flexible and rigid packaging. These technologies are packaging machine brand independent and enable customers to realize better packaging quality, higher packaging productivity and end-of-line automation. Engilico’s technologies provide package integrity and ensure shelf-life, therefore increasing customer satisfaction and improving the brand image of leading international companies within the global food, pet care, and other applicable industries. Engilico has a worldwide presence and became part of the PACRAFT group, a subsidiary of Nabtesco (Tokyo, Japan) in 2021.

About PACRAFT
For more than 60 years, PACRAFT (formerly Toyo Jidoki) has been innovating and supplying pre-made pouch-filling and packaging equipment. Headquartered in Tokyo (Japan) with a subsidiary office in Chicago, PACRAFT is part of the Nabtesco group. PACRAFT has an installed base exceeding 10,000 units and has subsidiaries in 4 countries and distributor partners in more than 40 countries and regions. – pacraft-america.com

About Matrix Packaging Machinery
Matrix is an industry leading manufacturer of rugged, cost competitive, and easy-to-use vertical form fill seal (VFFS) equipment for all types of flexible packaging and operates as a master distributor of INVpack stickpack and sachet machines, PACRAFT pre-made pouch packaging machines, and Cetec Industrie flexible bagging machines . With more than 30 years of flexible packaging expertise, Matrix has the ability, knowledge, and commitment to tailor highly efficient and profitable packaging systems for our customers on a global scale. Matrix is a product brand of ProMach, a global leader in packaging line solutions. As part of the ProMach Flexibles & Trays business line, Matrix helps its packaging customers protect and grow the reputation and trust of their consumers. ProMach is performance, and the proof is in every package. Learn more about Matrix at www.MatrixPM.com and more about ProMach at www.ProMachBuilt.com.

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Mobergs Produktkontroll AB, the leading Scandinavian supplier of product control and material sorting equipment for the manufacturing and food processing industries, adds Engilico’s in-line seal inspection solution for flexible packaging to their range of quality control solutions. The SealScope® system provides 100% seal inspection and enables Moberg’s customers to realize better packaging quality and productivity.

The sealing of flexible packages is a crucial step in many food packaging processes. Product in seal, wrinkles, pleats, or folds can lead to imperfectly closed packages with an immediate negative effect on shelf life, customer satisfaction, and even brand image. An in-line, 100% seal inspection system tackles these challenges.

SealScope® is an easy-to-integrate and non-destructive in-line seal inspection and process monitoring technology for flexible packages such as VFFS baggers, flow wrappers, pouches etc.  The innovative SealScope® system uses sensors mounted on the sealing bars to detect undesired product in the seal or folds, which can lead to open packages. Every produced package is instantly compared to a reference seal and when sealing errors are detected, a signal is sent to a rejector to automatically remove the defective packages from the conveyor belt. In addition to inspecting every individual product, SealScope® also monitors the quality of the complete packaging process. Because each package is measured, it is also possible to register trends and deficiencies in the production process. In this way, if the rejection ratio increases, the packaging can automatically be paused and pro-active maintenance can be done, avoiding unplanned production stops.  Also, the productivity levels can be optimized to find the right balance between outgoing quality, packaging speed and rejected packages.

As the SealScope® sensors are directly mounted on the sealing bars, there is no need to change the layout of existing packaging lines. The easy-to-install SealScope® integrates with major brands such as GEA, Bosch, ULMA, Rovema, Omori, Fuji packaging, PACRAFT (formerly Toyo Jidoki), SN Packaging, LeePack and many more. The SealScope® inspection is perfectly suited for products where sealing integrity is of critical such as (sliced) meat and cheese, fresh produce, fruit, ready meals, cereals, tortillas, powders, pet food and many more

“We are very excited to have this innovative in-line seal inspection for flexible packaging lines in our offering.”, says Anders Johansson, “It is a very beneficial technology that can help our customers to improve packaging quality and productivity.”

We are delighted to partner with the Mobergs’ experienced team of quality control specialists.”, adds Olivier Georis, CEO and managing director of Engilico, “This is an excellent opportunity for Engilico to offer SealScope seal inspection to customers in the Scandinavian market.”

About Engilico

Engilico (Rotselaar, Belgium) delivers innovative technologies to inspect, monitor and optimize the sealing process of flexible and rigid packaging. These technologies are packaging machine brand independent and enable customers to realize better packaging quality, higher packaging productivity and end-of-line automation. Engilico’s technologies provide package integrity and ensure shelf-life, therefore increasing customer satisfaction and improving the brand image of leading international companies within the global food, pet care, and other applicable industries. Engilico has a worldwide presence and became part of the PACRAFT group, a subsidiary of Nabtesco (Tokyo, Japan) in 2021. – www.engilico.com .

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Kneipp improves their packaging process with in-line seal inspection

Today we visit the Kneipp® Oberhauser plant near Würzburg with Mrs. Heilscher, responsible for lean manufacturing. In this modern production plant, a wide variety of products are processed, including bath, body care, and even nutritional supplies.

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For Sebastian Kneipp, water was everything. He was known as the “Water Doctor” in Europe, pioneering hydrotherapy 130 years ago. People came from afar seeking his healing expertise and that tradition continues today. Only now, with the naturally pure bathing salts, one can experience it in the soothing comfort of its own bathtub. The perfumed crystals packaged in easy-to-use sachets require perfect sealing to prevent leaking crystals, aromatic loss and cosmetic seal deficiencies.

Unique deep salt

The primary ingredient of the Kneipp bath salts are natural salt crystals, whereby for certain product series the renowned Luisenhall deep salt is used. This originates from the Luisenhall salt works and is extracted at a depth of 460 meters from the brine of a 250-million-year-old primeval sea. While the crystals of evaporated salt have a rough, but closed surface, deep salt has a kind of crater landscape. With the help of these tiny cave systems, the salt crystals can literally absorb essential oils. In water, the bath salt dissolves and releases the active ingredients. Unlike many other salts, the primal salt in the depths of the Luisenhaller earth is protected from environmental pollution – and therefore free from harmful residues from fine dust and exhaust fumes.

Packaging in sachets

The precious salt crystals are packaged in sachets on different packaging lines including a rotary pouch/sachet packaging line and a horizontal-form-fill-seal (HFFS) machine. As Kneipp is associated with outstanding quality products, there is a definite need for in-line seal inspection of the sachets to guarantee the outgoing product quality. As salt is a brittle product, it will contaminate the seal if it gets crushed between the sealing bars during filling and sealing phase. With the high production volumes of up to 60.000 packages per day, it is nearly impossible to manually inspect every single sachet. This is why Kneipp was looking for an automatic, in-line seal detection solution.

In-line seal inspection is key to reduce manual QC
Kneipp learned about the automated, in-line SealScope® solution while visiting an international packaging tradeshow. The in-line seal inspection system instantly caught my attention.“, comments Frau Heilscher, “This could definitely address our inspection needs for the bath salt packaging lines.”

The innovative SealScope® system uses sensors mounted on the sealing bars to detect undesired product in the seal or folds, which can lead to open packages. Every produced package is instantly compared to a reference seal and when sealing errors are detected, the defective packages are automatically ejected from the conveyor belt. As bathing salt is a precious product, the rejected products are reworked, so there is no production waste.
At first, the rotary packaging line was equipped with SealScope® to verify seal defects such as salt that is stuck in the seal. Even when the seal itself is not breached, product in seal is not acceptable for esthetic reasons. SealScope® also detects folds or plies in the sealing area which can also lead to leaking packages. This is equally important to avoid the salt losing its aromatic qualities or spill in the final carton end-packaging box.

“Before using SealScope we had to manually eliminate bad sachets from our production, which was an inefficient process.”, comments Herr Klaus Müller, Technical Director Kneipp, “By using our automated seal inspection, we are able to eliminate nearly all defective packages in the production output.”
With the high amount of product variations and package sizes, SealScope® is also highly suited to keep all the production data stored per product type. A change in product requires about half an hour to replace the foil and clean the product fillers. SealScope® records all data per new production batch, so that eventual errors can be traced back to the exact product data.

Monitoring function supports lean manufacturing
But there is more. Another interesting function of SealScope® is the monitoring of the packaging process. Because each package is measured, it is also possible to register trends and deficiencies in the production process. In this way, if the rejection ratio increases, the packaging process can automatically be paused after e.g. ten defective packages and maintenance can be done. Or the machine can be timely adjusted, which can prevent production of bad packages and production delays. Typical issues can occur with small foil parts or salt that are built on the heated sealing bars.

From environmental perspectives, this is also beneficial to reduce plastic film waste as the production is instantly stopped when there are occurring consecutive sealing issues.
Also highly valued is the remote support via TeamViewer. In the rare case there is a technical question or issue with the seal inspection system, the Kneipp team can consult with the support team in Belgium, who can directly access the installation to provide assistance. This avoids enduring and expensive support visits.

“We learned about the automated, in-line SealScope® solution on a tradeshow. The in-line seal inspection system instantly caught my attention, as it could definitely address our seal inspection needs for the bath salt packaging lines.” – Frau Heilscher – Lean Manufacturing

Further deployment of seal inspection automation
As Kneipp is gradually automating the production and packaging, in-line seal inspection will continue to play an important role in further upgrades of packaging lines. “We are definitely pleased with the automated seal inspection solution.”, concludes Herr Müller, “The implementation of SealScope® is resulting in automated quality control, better process management and cost reduction on manual labor.” Also, our quality requirements are very challenging, as we need to comply as well to pharmaceutical, cosmetics and food standards. In this sense, the in-line seal inspection fits perfectly in the quality philosophy of Kneipp.

Another interesting project is being investigated for inspecting the end seals of tubes for e.g. shower and shampoo gels. Kneipp and the research team of Engilico are evaluating the use of hyperspectral imaging, with the purpose of detecting leaks in the opaque seals of the tubes. As such, Engilico’s seal inspection can be a solution to the challenges of today and tomorrow.

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In-line hyperspectral seal inspection enables end-of-line automation for packaging snack trays

Since 1949, one of the most popular television and party snacks has been produced in Austria: the thin, salty pretzel sticks from the brand Soletti. Meanwhile Soletti became part of Kelly Snacks, and the successful product of flour, water, salt and yeast is exported to more than 40 countries. To keep up with the continuous growth, Kelly most recently invested in two new production lines for packaging various types of trays. A key element for these salty snacks is to preserve the crispiness, so seal integrity is critical. That’s why Kelly also integrated two new HyperScope® systems into these production lines, for fully automatic and 100% in-line seal inspection of the single- and multi-compartment trays with transparent as well as printed films.

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Soletti’s product assortment has been extended over the years, offering a host of tasty nibbles and snacks, packaged in various formats, such as bags, trays, flow-packs and cups. Soletti is committed to use raw Austrian ingredients and sustainable production methods – an indispensable approach for an unbeatable flavor.
In 1985, Kelly acquired Soletti’s “Feldbacher Backwarenfabrik”, which was the largest baking production line for salt sticks in Europe at the time. In 2008, Kelly joined the Intersnack Group and Feldbach became the European Center of Excellence for baked products within the Kelly and Intersnack Group from 2010-2020.

“With 12,000 tons per year, Kelly is one of the largest industrial buyers of Austrian flour from Pregarten near Linz, Schwechat and Klagenfurt. The salt is sourced exclusively from the Salinen company in Ebensee in the Austrian Alps and processed at the plant.”, explains Mr. Matthias Stoessl, “Every day, 50 million salted sticks go through the baking line. The Soletti Pretzel recipe is a closely guarded secret, as is the production process.”

A diverse range of packaging

Snacks are packaged in different variations for many occasions: small personal treats, movie portions or bigger sized servings for families and parties. This requires different packaging formats such as flow-packs, VFFS (gusseted) bags, cups or thermoform trays with multiple compartments. To guarantee best-before dates and offer an appealing product, seal inspection is essential to avoid leaking packages or visible product particles in the sealing area. As the demand for snacks in trays is growing, Kelly decided to expand/upgrade their production capacity with new fully automated lines for packaging single trays, dual trays, or even quadruple trays with a mixed variety of snacks.
As seal integrity is equally important for these types of trays, Kelly was looking for a solution to inspect in-line 100% of the seals and automatically remove faulty packages, overall reducing manual labor for inspection and sorting. Defective packages lead to internal and external quality problems and high sorting costs, which of course need to be avoided.

Challenges with crispy snacks

There are different challenges with this type of product and its packaging. As the salted product is crispy there are crumbles that might get stuck in the sealing area. When these particles are small, they have a limited effect on seal integrity. But larger parts can result in a seal breach.
As the top film of the packages is often printed, contamination cannot be “seen” by a human eye or standard vision inspection systems. Inspecting with a camera from the bottom is also not a solution as the crumbles are hardly visible as there is typically a low contrast between the crumbles and the pale underside of the film, and certainly not when the tray is opaque.
Also, at a high production rate, manual inspection is simply not feasible. Finally, with multi-compartment trays there are often issues with product particles in the bridge. Also in this case, viewing or inspecting from below is difficult as the steep walls of the trays easily block the view of camera. So ideally, Kelly was looking for a solution that was: 1) capable of detecting contamination ; through printed top film; 2) usable for multi-trays; 3) capable of handling high production speeds and; 4) automatically rejecting faulty packages.

Enters HyperScope®, Engilico’s new solution for hyperspectral-based seal inspection of rigid trays and thermoforms.

Convincing remote demonstration
Kelly was already familiarized with Engilico’s solutions for seal inspection of flexible packaging. When Engilico introduced a revolutionary seal inspection system for rigid trays in 2021, Kelly was immediately interested in performing tests as they were planning to automate the inspection of their tray production lines. During that time however, the Corona pandemic was imposing severe restrictions on travelling and visiting customers on-site; a remote demonstration was organized using different types of packages that were sent to Engilico HQ for testing. After a successful demonstration, Kelly decided to equip their production lines with two of these unique hyperspectral seal inspection systems.

Seeing more with hyperspectral imaging and AI
HyperScope® uses hyperspectral imaging to detect seal contamination with high contrast, even with printed film. The inspection system features GPU-accelerated artificial intelligence (AI), which enables real-time, high-precision seal area detection, regardless of the package orientation, packaging material, layout and size. The system includes a conveyor belt that can be completed with an integrated reject unit.
Hyperspectral cameras capture information from a larger part of the electromagnetic spectrum including infrared wavelengths that penetrate through thin plastic or paper top films. Hyperspectral imaging, therefore, unlocks new inspection possibilities where classic imaging often falls short, e.g., on printed film packages which are often used in the range of premium products with luxury packaging, on packaging with opaque backings or in applications where the seal contamination is difficult to detect due to limited contrast. The system can inspect up to 160 packages per minute, a speed that is well aligned with sliced, chopped and/or bulked-food production lines.
In-line seal inspection using hyperspectral imaging is challenging – as packages on the conveyor belt have different orientations. Moreover, the package surface might also be slightly deformed, especially when lighter materials are used – a trend nowadays to reduce plastic waste. Since contamination only needs to be detected in the sealing area, it is particularly important to detect this region with high accuracy. HyperScope® relies on artificial intelligence for this task: the sealing area is automatically determined, regardless of package orientation, degree of deformation and number of tray compartments.
The detected sealing area is then further analyzed in several post-processing steps to detect e.g. seal breaches, contamination inclusions in the seal, etc. Finally, based on configurable decision criteria the package is accepted or rejected.

“It is very important for us that 100% of our production is inspected and packages with seal contamination can be removed from the packaging line.”, says the IWS Manager Mr. Matthias Stoessl, “Seal defects can have an impact on the freshness of the product. Also for aesthetic purposes, product inclusion in the sealing area is not acceptable.”

Smooth installation and deployment
The internal conveyor was specifically designed to fit in the layout of the production line. As the tray packaging lines were newly configured, the installation was relatively straightforward, teaming with the professionals from Kelly as well as with an external third-party line integrator.
HyperScope® is capable of processing different products and variations, which is important as the packaging lines are producing for different brands. In total, more than 16 different product models were created and extensively validated. All daily inspection information for the different products is saved in a database that can be exported to many reporting formats.

“We are very pleased with the installation and deployment of the two HyperScope® systems. This is a very innovative inspection technology that is particularly suited for our multi-compartment packages with printed top film.”, concludes Mr. Stoessl, “The new fully automated packaging line that features metal detector, HyperScope® seal inspection and checkweigher, positions us at the forefront of production and inspection capabilities.”

Monitoring production quality and process
As 100% of the production is tested, HyperScope® also serves as a monitoring tool for the complete production and the packaging line. When an issue occurs earlier on the line, and packages with defective seals are detected, operators can immediately take corrective actions. As an example, such a case occurred when the parameters of the thermoforming machine were wrongly configured, due to changing of packaging formats: typically, before sealing, the filled trays are automatically cleaned with a brushing tool to remove crumbles, but due to a wrong setting of the height of the brush, an unusual increase of defective packages was detected by HyperScope® and operators could immediately correct the wrong height setting.
Being a center of excellence, other companies from the Intersnack Group are obviously very interested in following these latest innovations at the Feldbach production site.

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