An Ishida AirScan in-line leak detector has been implemented at Eisberg’s Polish factory to ensure the highest seal integrity for their extensive range of ready-to-eat fruits and vegetables in modified atmosphere packaging. As one of Europe’s leading manufacturers of fresh convenience salads, vegetables, and fruits, Eisberg prioritizes quality and safety in food and beverage packaging.
By utilizing the Ishida AirScan, Eisberg has significantly elevated the quality and safety of its products. This advanced leak detection system ensures that their offerings remain fresh throughout their entire shelf life. Furthermore, by automating what was previously a labor-intensive quality check, the company effectively addresses the ongoing labor shortage within the sector.
Founded in Switzerland in 1972, Eisberg now operates seven production facilities across Europe. It stands out as the top supplier of convenience fresh produce in Switzerland and Central and Eastern Europe (CEE). The Polish factory opened in 1992, followed by the Romanian facility in 1995, contributing to the growing popularity of salads in the CEE region.
Quality has always been Eisberg’s top priority. To enhance their seal integrity checks for both pillow pack and tray formats, they sought a more reliable solution. The previous off-line tub and water method was not only laborious but, as Eisberg’s technology manager Damian Bańkowski puts it, “somewhat makeshift.”
“The arrival of the Ishida AirScan has elevated our inspection process to a higher level of automation,” he stated. “With the difficulty in recruiting the right personnel, we now possess a system that operates independently of human intervention, ensuring fully automated inspection of our products for complete seal integrity.”
The Ishida AirScan, designed for a wide variety of foods, employs advanced laser technology to quickly and reliably detect CO2 leaks from holes as small as 0.5mm. This system lightly pressurizes each package while testing the surrounding air for traces of excess carbon dioxide.
At Eisberg, the Ishida AirScan checks packages for CO2 leaks caused by poor seal integrity, physical damage, product-in-seal incidents, as well as compromised seals resulting from incorrect parameter settings on the packaging machine.
The AirScan has been seamlessly integrated into the packing line, inspecting approximately 35 packs per minute. It operates eight hours each day, with Eisberg reporting reliable performance and product changeovers typically taking less than a minute.
“The Ishida system is intuitive and can be operated by anyone following brief training,” noted Damian Bańkowski.
The installation was facilitated by Ishida’s Polish agent, Fenix Systems, which provided an enclosure around the machine to shield it from airflow generated by upstream equipment, thereby maintaining accuracy. Fenix also delivered comprehensive training for both the technical team and line operators.
“Thanks to the AirScan, we can now conduct thorough in-line seal integrity testing, providing both ourselves and our customers with full assurance regarding the quality and safety of our products,” concluded Damian Bańkowski.
“Our decision to invest in Ishida was driven by the recommendations and experiences of our colleagues elsewhere in the group, who were already utilizing Ishida technology, and it has undoubtedly proved to be the right choice. We plan to install additional Ishida equipment in the future, including more AirScan systems.”
