Leak Detection Module — Dual-Pull Aspiration Testing

VeriPak Add-On Module

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

Dual-Pull Differential Suction

How It Works

Controlled Aspiration

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

Differential Aspiration

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-Z 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.

Binary Output

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

Line-Speed Compatible

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

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Integrated with VeriPak SCADA

Every leak detection event feeds directly into the VeriPak platform in real time — 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. VeriPak fuses leak integrity data with vision inspection data into a single reject decision.

System Architecture

Where It Fits in the Line

See how this solution integrates into real production line configurations. Explore AQS products in this line.

AQS's strongest full-ecosystem story. Leak detection after the thermoformer removes the manual touchpoint — once the person is out of the loop, robotic case packing becomes possible. VeriPak sits underneath as the decision engine, fusing leak detection data with vision inspection into a single reject decision and unified product record.

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IntelliPak

Infeed Timing

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Thermoformer

Form & Seal

You Are Here

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VeriPak

Inspection + Leak

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Reject