Plastic container manufacturers are improving their quality assurance programs by integrating empty rigid container inspection into their processes. This type of container inspection not only ensures package integrity and consistency but also helps reduce waste, enhance customer satisfaction, and protect brand reputation.
By improving overall profit and cost efficiency, ALPS Inspection systems act as a reliable insurance policy for converters, safeguarding their investment and reputation.
Introducing BenchPlus® Manual Leak Tester
As a global leader in continuous leak testing equipment, ALPS Inspection understands that situations require quick, reliable testing outside the production line. With those challenges in mind, our expert team collaborated with blow molding manufacturers to develop the ALPS BenchPlus® Leak Testing System.
There are four key ways converters can use this versatile yet simple single-head bench top system to improve quality assurance programs and support new product development.
1. New Container Design and Material Testing
Container inspection is essential for blow molding companies and eco-friendly bottle converters considering design or composition changes. BenchPlus is a powerful addition to research and development (R&D) and quality assurance (QA) teams. It offers convenient yet comprehensive testing and helps identify issues in any new design that could compromise product integrity.
BenchPlus supports packaging changes in three key areas:
- Inspecting New Container Designs: Provides rapid, reliable data to verify new designs meet existing performance standards.
- Inspecting New Raw Materials: Confirms that new resins, especially those made with PCR or other sustainable materials, will not cause defects or adversely affect finished product performance.
- Inspecting During Scale-Up: Facilitates testing at every stage of R&D, allowing manufacturers to identify issues resulting from even the most minor process or raw material change.
Learn everything you need to know about navigating rPET sustainable packaging defect inspection.
2. Off-line Random Sampling
In-line leak testing systems are integrated into your manufacturing line and optimized to meet production requirements. When the leak testing system is running the usual production, BenchPlus allows you to perform R&D or validation testing off-line, providing additional in-depth testing without disrupting the production line.
Other benefits of off-line testing with BenchPlus include:
- Informed Leak Tester Adjustments: In-line systems' testing rate and duration are set to meet specified quality standards. User-friendly BenchPlus technology enhances this by allowing operators to categorize hole sizes with extended test durations off-line. This provides valuable insights, enabling plants to make informed, as-needed adjustments to the in-line system. Additionally, it helps determine if an obsolescence upgrade or a new system is required to meet evolving inspection standards, changes in design or material, or increased line speeds.
- Enhanced Quality Assurance: Performing random sampling with BenchPlus gives you the opportunity to verify your in-line system is set up and properly operating. In other words, it’s the ideal supplemental tool for testing the overall accuracy of your in-line ALPS Inspection system. If an issue is identified, it provides guidance on how to adjust accordingly.
Watch this video to see the BenchPlus Manual Leak Tester in action.
3. Lab Testing
Lab testing is a regular, detailed examination of containers conducted in a dedicated QA lab. It offers more control and thoroughness, allowing for extended testing times and comprehensive quality checks. Random lab testing can provide valuable product evaluations during new product trials, process changes, or occasional process validation.
Whether in a room outside the production area or an isolated area on the production floor, a dedicated QA lab space provides a controlled environment where technicians can inspect production samples without disrupting the production line.
Unconstrained by the pace of production, QA technicians can use BenchPlus to conduct additional or extended testing that can help identify smaller leaks or defects, which can also help give you better insights into bigger production issues.
The BenchPlus® Manual Leak Testing System’s compact footprint and portable design make it ideal for benchtop testing in a QA space. Learn more.
4. Select, Slow Applications
While BenchPlus was designed as a supplemental leak tester to your in-line leak testing system, it can be suitable for a slow blow molding application where production speeds are slow enough to allow for manual leak testing.
For example, if a plant produces only a few large containers per minute, BenchPlus would allow for 100% inspection without needing to invest in a fully automated in-line leak testing system.
A cost-effective solution for small-volume blow molders, this benchtop leak tester also provides adaptability and cost savings for high-volume manufacturers running the occasional small or specialty order. Though less frequent, converters may get container sample requests from brand owners, prompting low-volume production on their pilot line.
Why Choose BenchPlus?
The BenchPlus Manual Leak Tester is an invaluable tool for rigid plastic and eco-friendly packaging converters seeking to add that extra layer of assurance, ideal for applications including Injection-Stretch Blow-Molded (ISBM) or Reheat-Stretch Blow-Molded (RSBM) PET containers, Injection-Blown-Molded (IBM) pharma bottles, and Extrusion-Blown-Molded (EBM) bottles. From slow- to high-speed production, BenchPlus provides comprehensive off-line leak testing solutions guaranteed to ensure product quality and fuel innovation.
