A seal channel half a millimeter wide is invisible to a line worker glancing at a passing package, and it is exactly the kind of defect that does not show up as a problem until the package is already palletized, shipped, and sitting on a retail shelf losing shelf life days ahead of schedule. Vision inspection alone can catch a visibly wrinkled or misaligned seal, but it cannot confirm an actual seal failure the way a vacuum decay test can, and relying on either method alone leaves a real gap in coverage. Combining both closes that gap before finished cases ever leave the plant. See leak and weak seal detection running on your own packaging line.
Catch the 0.5mm Channel Before It Ships
iFactory AI combines vision inspection and vacuum decay testing to catch leaking and weak seals before finished cases are palletized.
A Seal Can Look Fine and Still Leak
A seal that looks visually acceptable can still have a microscopic channel too small for even a trained eye to catch, and that gap between what vision can see and what actually constitutes a functional seal is precisely where leaking packages slip through an inspection process built on visual checks alone, which is why seal integrity needs to be confirmed, not just observed.
Vision Inspection
Catches visible seal defects: wrinkles, contamination, misalignment, and gross gaps.
Vacuum Decay Testing
Confirms actual seal integrity by measuring pressure change, catching channels invisible to vision.
Confirm Seal Integrity on Your Own Line
Book a 30-minute session and see combined vision and vacuum decay detection running on your own packaging line.
What Each Method Catches, and Misses
Neither method alone provides full coverage, which is the entire case for running them together.
| Method | Catches | Misses Alone |
|---|---|---|
| Vision only | Visible wrinkles, contamination, gross misalignment | Microscopic channels with no visible sign |
| Vacuum decay only | Actual seal integrity failures, down to sub-millimeter channels | Cosmetic defects that do not yet affect integrity |
| Combined | Both visible defects and confirmed integrity failures | Full coverage across the defect spectrum |
From Package to Pass or Reject
Both checks run within the line's existing cycle time, with a clear path for a package that fails either one.
Rolling Out on the Packaging Line
iFactory AI connects vision cameras and vacuum decay equipment to the line, calibrated to each package format's specific seal spec.
Expert Review
Vacuum decay testing earns its place fastest when it is shown catching a package that passed vision inspection cleanly, since that comparison is what convinces a quality team that visual checks alone were leaving real exposure on the table, not just a theoretical gap.
Frequently Asked Questions
Does vacuum decay testing slow down the packaging line?
Testing is designed to run within the line's existing cycle time, so it does not introduce a separate inspection step that reduces throughput. Support can confirm cycle-time impact for your line speed.
What size channel can vacuum decay testing actually detect?
Detection sensitivity depends on the specific package and test parameters, with sub-millimeter channels typically detectable once the method is properly calibrated to that package format.
Can this work on different package formats on the same line?
Yes, seal checks are calibrated per package format, so the same line can switch between formats while detection adjusts automatically. See multi-format calibration on a call.
What happens to a package that fails the vacuum decay test?
A failed package is automatically diverted for rejection, with the specific failure type logged against the seal station and time for trend analysis.
Does this integrate with our existing quality management system?
Yes, defect and failure data can feed into your existing quality management and SPC systems rather than requiring a separate standalone report. Ask support about QMS integration.
Confirm the Seal, Don't Just Look at It
iFactory AI combines vision and vacuum decay testing to catch leaking and weak seals before cases are palletized. Book a demo on your own line.
