Syntegon’s KLD Series detects leaks in ampoules and vials at up to 24,000 containers per hour. The high-voltage leak detection method is based on electrical current measurement on the mA scale, and involves applying voltages of up to 30kV across containers filled with conductive liquids. An increased electrical current indicates a breach in the isolating container wall.

  • Reliable results for water-based products even with low conductivity and low fill
  • Pre-wetting, utilising belt or vibration plate option, and active 360° rotation of the container to cover the entire inner surface with liquid
  • Four independently adjustable testing stations
  • Smooth and stable transport system combining servo-driven scrolls and belt systems
  • Compact and accessible design, available as standalone or in-line solution
  • Integrated electrical cabinet

For recipe creation, performance evaluation and verification, the same sequence of samples can be reloaded multiple times and the machine automatically compiles data for each channel and sample. Bar charts are provided on HMI and as printable reports, including individual values.

Details of the measurement system

The containers are tilted to horizontal position and are actively rotated by at least 360° on four independent, individually adjustable testing stations.

Besides the rotation belts along the electrodes, the pre-rotation belt or the stronger vibration plate with adjustable speeds facilitate wetting, especially for low filled containers. The proven setup of bar electrodes from below offers significant advantages: the distance between container and electrode is minimised and remains constant, which reduces measurement variability. The wetting of the inner container wall near the electrodes is also improved.

These effects ensure high detection rates and low false reject rates, even for low-filled containers or liquids with low conductivity (eg. WFI). Performance can be conveniently evaluated and verified using a special test mode with graphical assistance and detailed reporting.

The changeover for the total machine can be carried out in less than 20 minutes. It is not only fast, but also very convenient for the operator: no tools are required and only around 20 parts need to be replaced, none of which weighs more than 8kg. In the event of glass breakage in the machine, the complete electrode module (including belts) can be taken out quickly and easily. Good accessibility and lean design allow easy cleaning, keeping machine down-times to a minimum.