VeriPak Module \u2014 Patent Pending

R&D

Leak Detection Systems

Zero Leakers. Zero Guesswork.

Vision systems inspect what a package looks like. Our dual-pull suction system tests whether it's actually sealed — detecting pinholes, grease-in-seal, and board cuts that cameras physically cannot see.

See How It Works →Join the Founding Partner Program →

Part of the VeriPak Ecosystem

Leak detection runs on VeriPak's Allen-Bradley controls platform. Every test result feeds directly into VeriPak SCADA — logged, trended, and fused with vision inspection data into a single reject decision. The leak test becomes part of each package's verifiable identity.

Learn about VeriPak →

The Real Cost

A Leaker That Reaches Retail Costs More Than the Package

When a leaking package makes it past your line and onto a retailer's shelf, the cost isn't just the product. It's the chargeback. It's the consumer complaint that shows up on social media. It's the product hold triggered by a failed shelf-life test. It's the recall exposure from a seal integrity failure that nobody caught.

Most plants run vision-based leak detection or no inline leak detection at all. Vision can verify labels, code dates, and surface cosmetics. But a pinhole smaller than a camera pixel, grease trapped inside a seal zone, or a micro-puncture from an L-board edge are physically invisible to optical inspection at production line speeds.

These are the leakers that reach retail. And every one of them is a physics problem — not an optics problem.

< 1px

Typical pinhole size vs camera resolution

Vision detection rate for grease-in-seal

300+

Packages/min at production speed

Distinct leak failure modes

Our Approach

We Don't Look at the Package. We Test It.

Dual-Pull Differential Suction Detection

Instead of looking at a package, we test it. Our system applies calibrated suction to the package surface in two consecutive pulls and measures the force response and surface deflection on each pull. A sealed package produces consistent, repeatable readings. A leaking package shows measurable delta between pulls as atmosphere enters the compromised seal.

First Pull

Calibrated suction cup engages the package surface. System measures the force required to achieve target deflection and records the package’s resistance profile.

Second Pull

Identical suction applied immediately after. A sealed package reproduces the same force/deflection curve. A leaking package — even with a pinhole — shows measurable atmosphere ingress.

Delta Analysis

The force differential and deflection delta between pulls are compared against known-good baselines. Any deviation beyond threshold triggers reject. Binary pass/fail — no interpretation needed.

Why Differential Measurement Works

Physics, Not Pixels

Detects actual atmosphere ingress through any breach — pinholes, grease in seal, board cuts, micro-tears — regardless of visual appearance.

Self-Referencing

Each package is its own baseline. The first pull establishes the reference. No calibration drift, no ambient light issues, no camera focus problems.

Binary Output

Force delta exceeds threshold → reject. No ML model interpretation, no confidence scores, no false-positive tuning nightmares.

Line-Speed Compatible

Mechanical actuation at production speed. No image processing latency or frame-rate limitations.

What Vision Systems Miss

✕Sub-pixel pinholes in forming film

✕Grease trapped inside seal zones

✕L-board edge micro-punctures from inside

✕Incomplete initial/final seal overlap

✕Fat or scrap contamination in seal area

✕Film wrinkle defects under the seal surface

✕Low vacuum without visible seal defect

✕Cascading die contamination from prior packages

Deep Domain Expertise

We Know Every Way a Package Fails

Our system is designed around exhaustive knowledge of real-world packaging failure modes — not theoretical defect models.

Film Pinholes

Micro-punctures from burrs on rollers, exit chutes, or lazy susans. Often invisible to camera systems — too small to resolve at line speed.

Board Cuts

L-board edges puncturing forming film from inside the package. Occurs along board edges or flaps when boards aren't lying flat.

Board in Seal

L-board material encroaching into seal area, creating incomplete seals. Caused by misalignment, timing issues, or infeed plate angles.

Fat / Meat / Scrap in Seal

Product contamination in the seal zone — from bacon length variance, cold meat creating scrap, or wafer slices from the slicer.

Grease in Seal

Bacon grease trapped in seal from earlier contamination events. Foreign material on the die seal area creates cascading failures across multiple packages.

Initial & Final Seal Leaks

Compromised seals from foreign material on seal bars, incorrect heat settings, or worn bushings creating insufficient overlap between initial and final seals.

Film Wrinkle / Misalignment

Insufficient film tension or misalignment creating wrinkles that prevent proper seal formation. Partial rolls without brake pressure are common culprits.

Low Vacuum

Trapped atmosphere from insufficient vacuum pressure, leaking hoses, or incorrect seal timing. Package lacks vacuum-tight appearance.

Platform Integration

Not Just Detection — Proof.

This is what makes AQS leak detection fundamentally different from any standalone system: the leak test result becomes part of the package's verifiable identity.

Every test feeds directly into VeriPak SCADA — logged by timestamp, SKU, operator, and defect classification. Force curves and deflection data stream into live dashboards for immediate operator feedback, shift-level trending, and audit-ready compliance reporting.

When a customer disputes a shipment or an auditor questions seal integrity, you don't defend with “our equipment was running.” You pull up the specific package record — the force curve, the deflection data, the timestamp, the operator — all tied to that individual package.

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VeriPak Logged

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Real-Time Reject

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Trend Analysis

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Alert System

Runs on VeriPak Controls

Leak detection shares VeriPak's Allen-Bradley CompactLogix PLC and Optix HMI. No separate controller. No data bridge. No additional enclosure. It's one platform, one data engine, one report — with leak integrity data fused alongside vision inspection, checkweigh, and metal detection.

Inline Detection

See What Vision Can't. Detect What Touch Can't.

For vacuum-sealed and MAP packaging, visual inspection isn't enough. AQS's dual-pull leak detection uses controlled aspiration and differential pressure analysis to mechanically test every package — inline, at full speed. Binary pass/fail. No ML drift. No false-positive fatigue.

SEALED TRAY

Package entering test zone...

Controlled Aspiration

Measured vacuum applied — initial structural response captured

Differential Aspiration

Second cycle measures deflection delta for comparison

Delta-Z Analysis

Deviation from baseline = leak detected. Binary pass/fail.

VeriPak Decision Engine

Fuses integrity + vision data into unified reject decision

Founding Partner Program

Be Among the First to Solve Leak Detection Right

We're selecting a limited number of production facilities to be among the first to run our dual-pull leak detection system inline. Founding partners receive:

— Priority pricing on the leak detection module
— Direct engineering support during installation and validation
— Input into the final production design — your line, your feedback, your influence on the product
— Early access to the technology before general availability

If you're running vacuum-sealed or MAP packaging and you're tired of vision systems missing leakers — this is your chance to solve it first.

Apply for the Founding Partner Program →

System Architecture