Seal Integrity Sensor Inspects Cups Inside the Filler

Using multiple sensors inside the cup filling system, the new SIT system from Teledyne TapTone can check for bad seals, damaged or deformed foil lids, and weak seals at speeds to 200 m/sec.

Teledyne TapTone’s new Seal Integrity Tester (SIT) is designed to inspect cups inside the cup filler. Using a patented design that consists of multiple sensors mounted inside the cup filling system, the SIT sensor inspects each cup by compressing the sensor head to the foil lid of the cup at full production machine speeds of 200 m/sec and higher. The sensors monitor the lid deflection during the compression cycle, and the digital signal processor board calculates the inspection merit values to accept or to reject containers with defective seals that fall outside user-set merit value limits. 

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The system can detect bad seals caused by product across the seal area during filling, deformed or damaged foil lids that cannot make a good seal, and weak seals that can be caused by a variety of issues, including out-of-range heater temperatures.

Says Teledyne TapTone, the SIT sensor uses state-of-the-art DSP processor technology and incorporates an easy-to-use PC user interface graphically displaying “good,” non-leaking cups in green and “bad,” leaking cups in red. Minimum leak detection specifications for the SIT system range from 0.006 to 0.008 in. (150 to 200 microns) with multiple inspection algorithms capable of not only seal integrity but also gross leaks and missing foil detection.


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The SIT system can integrate into an existing filler PLC using Ethernet Modbus TCP/IP or Ethernet IP and sensors that mount to a vertical travel bridge after the sealing heads in the filling/sealing system. The bridge will cycle up and down based on the filler index speed. Says Teledyne TapTone, bridge control will come directly from the filler PLC for perfect index timing.

To view demos from Teledyne TapTone (available through March 31, 2021) and to add the company to your MyConnects Planner, click here.

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