In dairy and beverage packaging, every container counts. Even the smallest leak can cause waste, downtime, and costly product loss. For manufacturers producing HDPE plastic gallon jugs for milk and similar beverages, reliable leak detection isn’t optional, it’s essential.
At ALPS Inspection, we help container manufacturers protect quality at every stage of production. So when one of our customers started running into problems with their existing trimmer mount leak testing system, they turned to us. We recommended our NexGen Rotary Leak Tester, which proved to be a true game-changer.
The Background: What This Dairy Operation Was Using—and Its Biggest Quality Problem
Our customer manufactures HDPE plastic dairy-style gallon jugs, common in milk and other beverage applications, and uses a trimmer mount leak detector to identify defects as small as 0.040 inches. They transfer these containers directly to their customer via a through-the-wall operation.
While the testing equipment and process they used had been working and were common across the industry for this container type, it was an older platform and technology, and limited in its sensitivity. As our sustainability-focused customer transitioned to a more direct connection with their customer, they wanted to increase their quality assurance as much as possible.
They had also been experiencing leaks on lines at other facilities that used trimmer mount leak detection and asked ALPS Inspection to help determine the source of the problems and how they could be solved.
The Challenge: Their Trimmer Mount Leak Tester Was Missing Pinhole Defects & Triggering Customer Complaints
Like many plastic container manufacturers serving the food and beverage industry, our customer was using a trimmer mount leak detector. Because this trimmer mount configuration requires a horizontal placement, it can only test containers handled horizontally. This positioning requirement limits testing capabilities concerning speed, handling, and test sensitivity. The trimmer is typically placed immediately after the blow molder, so containers are tested while still hot. Because cooler containers result in more accurate pressure decay leak test results, trimmer mount leak testers can negatively affect accuracy.
Our customer built a facility adjacent to the end customer’s, enabling them to use a through-the-wall connection to feed finished containers directly for filling. Space was at a premium in the new manufacturing facility. The close connection inspired our customer to seek the highest quality assurance possible, protecting their brand by delivering containers that would protect their customer’s brand, as well.
The Solution: Switching to the NexGen Rotary Leak Tester to Improve Container Quality
To deliver increased sensitivity in leak detection, ALPS recommended and installed the NexGen Rotary Leak Tester (NGR). Capable of much greater sensitivity than the standard but outdated technology the customer had been using, the NGR satisfies both the speed and sensitivity requirements of the customer.
NexGen Rotary: Detect Smaller Pinholes at Higher Speeds
The NGR is designed to ensure container integrity through high-speed pressure decay testing with excellent accuracy, able to detect defects as small as 0.004”-0.020” depending on the container. Defective containers are automatically detected and ejected. Available in configurations from 4 to 30 test stations, the NGR is capable of speeds up to 1,200 CPM (72,000 CPH). Containers are tested upright, handled with a continuous motion approach vs. the start/stop indexing of a trimmer mount system. Additional downstream and upstream sensors ensure the machine is running at the most efficient rate for conditions on the line.
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The NexGen Rotary Leak Tester delivers unmatched precision in dairy container leak testing, allowing manufacturers to detect smaller defects at faster line speeds while maintaining accuracy and consistency.
How The NexGen Rotary Fits Into Existing Dairy Container Processes
This application required creative layout and handling solutions to optimize efficiency and control within the limited space. Two separate blow molding lines in the customer’s operation were combined into a single line on a cable conveyor, which leads to an annealing oven, and rod chute before the NGR leak tester and vision inspection system.
The installation process highlighted the power of cross-team collaboration. As the customer’s project manager shared:
“From our initial design, installation, and through commissioning, the collaboration with our partners to enable real-time speed adjustments—where the entire line goes into high speed if a backup sensor is seen—was a huge collaborative win for the site and demonstrated exceptional teamwork.”
Including NGR in the line delivered an additional benefit: its container handling naturally creates the spacing required for accurate vision inspection. This layout requires less conveyor and increases the flexibility of controlling the flow of bottles from the customer’s blow molders through the wall to fillers at the end customer’s operation.
The Results: Zero Pinhole Complaints and Highest-Ever Overall Equipment Effectiveness
Shortly after going online, the customer’s project manager shared that:
“We are all pleased about what we are observing. So far this is world class.”
Our customer now sees results of higher leak testing sensitivity and greater cost savings from a reduction in rejects and associated waste. Achieving high quality in a through-the-wall operation also removes the cost (both financial and environmental) associated with packaging and transporting containers.
The end customer also reports greater efficiency in their dairy container leak testing operations, resulting from reduced rejects and overall increased container quality. They shared:
“We experienced the highest Overall Equipment Effectiveness ever this morning, so we are going in the right direction and adjusting other components as well.”
We are pleased to share that our customer now sends higher quality containers to their end customer, ensuring high efficiency and brand integrity, not slowed or damaged by filling faulty containers.
Delivering higher quality containers also directly increases speed while their operation avoids the cost and emissions of packaging and transportation. Keeping trucks off the road delivers wins not only for these two businesses but also for the community in which they operate.
Check out our full line of empty plastic container leak testing equipment.
Let’s Review: How This Dairy Container Manufacturer Benefited from Partnering with ALPS Inspection
Partnering with ALPS Inspection helped our customer elevate every aspect of their operation—from product quality to sustainability. By implementing the NexGen Rotary Leak Tester, they gained measurable improvements in efficiency, reliability, and overall performance.
Here’s how they benefited from elevating their inspection standards in the dairy container industry:
- Consistent, Reliable Quality: Upright rotary leak testing delivered more accurate, repeatable results, reducing defective containers and improving brand confidence.
- Faster, Smarter Production: The continuous-motion system increased line speed and efficiency while maintaining superior test sensitivity.
- Reduced Waste & Lower Costs: Improved accuracy led to fewer rejects and less material waste, generating significant cost savings.
- Greater Sustainability: The through-the-wall connection between the container manufacturer and end customer delivers immediate and measurable sustainability gains, avoiding the need to package and transport containers.
- Enhanced Line Visibility: Integrated HMI monitoring provided real-time insights, allowing operators to quickly identify issues and optimize performance. Finding and rejecting defects before containers are delivered to your customer protects your brand and your customer’s.
- Unmatched Service: ALPS Inspection's 24/7 service and support ensured minimal downtime and seamless integration from installation through commissioning. In closely-linked operations like this one, that means our customers’ success helps keep their customers online, too.
- Collaborative Success: The project’s success reflected close teamwork between ALPS, the customer, and their partners—delivering a high-performing, fully optimized line.
FAQs
Improve Your Dairy Container Quality with ALPS Inspection
If your operation still relies on a trimmer mount leak detection system, you may be limiting both efficiency and accuracy. As a leader in leak detection for plastic containers, ALPS Inspection designs adaptive, high-performance systems that test dairy containers upright, detect smaller defects, and improve line speed, all while reducing waste and downtime.
When you partner with ALPS, you gain more than innovative technology, you gain a dedicated team focused on maximizing quality assurance, reliability, and operational success.
Ready to upgrade your leak testing solutions? Reach out to ALPS Inspection today.