Equipment

Overview

The Grey Technical Area represents the largest workspace (approx. 450 m²), in which a flexible and demand-oriented division is possible. Due to existing projects, the additive manufacturing area as well as the development and design area are housed here, for example.

Selective laser sintering printer

The additive manufacturing zone is equipped with a 3D printer that uses selective laser sintering (SLS) technology, which enables the construction of polymer components from CAD data – without the need for tools or even supportive structures – in the build chamber measuring 200x250x330 mm. The ability to form one-off products with complex geometries is particularly useful for rapid-prototyping applications. The contour-accuracy of this process produces smooth surfaces that can then be post-processed to achieve the desired finish on-site.

Virtual Reality

Digitalisation using virtual reality

Our development and design team creates CAD data from original designs or by means of 3D scanning. Technical models are first refined and optimised in SolidWorks prior to validation in virtual reality (visualisation using 3D goggles). Once the models have been generated this way, we can discuss and continue to refine them in a virtual environment before moving on to create the physical product, thus saving a significant amount of time and expense.

Autoclaves

In the field of packaging solutions, autoclaves can be used to assess the thermal durability of packaging materials and identify any changes (mechanical, functional, structural) to their properties, also to trace effects on the packaged goods instrumentally and with sensors. We can also perform pasteurisation and sterilisation processes on products in our autoclaves.
For example, we can test new or alternative packaging materials, such as experimental plastic films, for comparison against reference products. If required, we can also generate supporting pressure.

E-Commerce test bench

The continuing trend towards online retail for food and consumer goods led us to construct a test bench specifically for packing solutions in this particular field, enabling us to examine how secure a packaging is, i.e. the mechanical protection of products, how well it controls temperatures (i.e. thermal protection), and the use of sustainable materials. Online retail, in particular, increases the demand for transporting refrigerated products in ways that maintain the legally prescribed temperatures and safeguard quality.

Temperature-control/ Refrigeration cells and precision-testing chambers

For testing exposure, we have a range of temperature-control and refrigeration cells alongside precision-testing chambers with additional climate control, including spacious refrigeration cells and a freezer in which we can regulate temperatures between room levels and deep freeze. There are also constant-climate chambers for storing samples at various temperatures and defined humidity levels (e.g. for testing exposure or simulating logistics and transportation), for example regulating conditions ranging from 10 °C and 70-80 % relative humidity to 70 °C and 10-80 % relative humidity. In addition, our precision-testing chambers can be used to subject samples to specific lighting conditions and temperatures (e.g. to simulate storage conditions in shops).

Overview

The white technical area (approx. 100 m²) creates an optimum basis for hygienic work with its separate product and personnel lock. This area offers a wide range of possibilities for the treatment and processing of food as well as the hygienic filling and packaging of sensitive products.

High Speed Tumbler

Our high-speed tumbler provides an innovative processing method for meat, rolling previously separate stages into one. A wide range of analyses can be conducted to evaluate changes in the meat’s structure and properties. Besides meat, other foodstuffs can also be subjected to this process if their texture is sensitive to pressure or shearing forces, such as mixed powders (seasonings), emulsions (mayonnaise or ointments) and manufacturing dough.

Filling system

Our clean-fill system can be used to fill liquid-to-viscous products hygienically. The ability to dispense small doses using this system is particularly useful. In combination with the temperature-control/refrigeration cells and precision-testing chambers, we can conduct extensive exposure experiments with subsequent sensory and analytical evaluations.

Tray-sealer

Our semi-automatic tray-sealer can be used to package small doses in various formats. Products can be dispensed into a range of packaging materials, enclosed in different protective gases, made ready for dispatch and then evaluated according to the required quality parameters.

Overview

The packaging materials lab is used for analysis of various types of packaging. The packaging materials (e.g. cardboard, film, etc.) can be examined mechanically, spectroscopically and microscopically with our equipment.

Materials testing machine

We can test packaging materials (foils, cartons, etc.) in the laboratory with the aid of a materials testing machine (10 kN all-round table-top), using its force transducers to test solid and/or durable materials, or those designed to withstand strong forces – both tension and compression. For example, we can examine the tensile strength of foils or conduct box compression tests (BCTs).

Microscope

The Packaging Laboratory is equipped with a microscope with universal white-light LED for illuminating materials and samples from either above or below. The attached camera means that images can be viewed and processed on a connected PC, while a rotary microtome can be used to process and produce precise microscopic sections as thin as 0.5 – 100 μm.

Spectrophotometer

Our Packaging Laboratory is equipped with a UV-Vis-NIR spectrophotometer. Depending on the field of application, an integrating sphere (e.g. for examining foils) or a cuvette holder (e.g. for examining liquid samples) can be deployed in the multi-purpose large sample chamber. Three sensors enable us to evaluate wavelengths ranging from UV, through visible, to near-infrared light for examining packaging materials, such as foils, with regard to reflection, transmission and absorption. In particular, the light-permeability of food packaging can be determined using the spectrophotometer and thus the effects on photosensitive products.

TMA

Thermomechanical analysis (TMA) makes it possible to examine the effect of simultaneous thermal and mechanical stresses on samples, tracing temperatures between -70 °C and 450 °C and forces of 0.001 N to 3 N at a resolution of 0.1 mN. By using a range of containers, we can conduct different experiments in varying ambient conditions to examine the sample’s tensile, dilatation, penetration and bending behaviour. Amongst other things, this makes it possible to detect the solid-to-solid transformation of a sample caused by temperature (e.g. glass transition of polymers) or determine materials’ specific thermal expansion coefficients.

FTIR infrared microscope

Our Packaging Laboratory is also equipped with an FTIR infrared microscope – combining an IRTracer‑100 spectral photometer (as the light source) and an AIM‑9000 microscope. 
The AIM‑9000 enables us, amongst other things, to measure thin sections of composite films with a minimal aperture of 5 x 5 µm in transition mode. We can use this to optically observe the construction of the composite and to determine its composition. In addition, the device has an ATR unit that can be used to analyse surfaces, particularly of opaque substances, such as coloured lacquer.

DSC

Differential scanning calorimetry (DSC) is a process that measures the amount of heat that a material absorbs or emits as it is warmed up or cooled. KLEVERTEC can use this method to examine materials at temperatures ranging from -40 to +600 °C. Measurements using DSC provide information about materials’ properties, such as glass transition or melting temperature, or a substance’s degree of crystallisation.

Gas transmissions tester

The gas transmissions tester (GTT) can determine the gas permeability of foils using various different test gases. The device has an electrothermic temperature control from 15 °C to 45 °C and can take measurements of volumes ranging from 0.05 cm³/(m² d bar) to 20,000 cm³/(m² d bar) without masking. It also possible to humidify test gases from 30 % RH to 90 % RH using this equipment. Since gas permeability is determined by the manometric method in accordance with ISO 15105-1, the device can be used to measure various different test gases, e.g. oxygen, carbon dioxide and nitrogen.

WVTR analyser

Our PERMATRAN‑W 3/34 permeation analyser is a state-of-the-art measuring system for determining the water vapour transmission rates (WVTR) of foils, coated papers and other smooth materials.  Its two independent, horizontal test cartridges with gas-flushed perimeter sealing (TruSeal) make it possible to conduct precise and highly accurate tests ranging from 0.05 g/(m² d) to 100 g/(m² d) (without masking). The fully automatic temperature, flow and FH controls enable measurements to be taken between 20 °C and 40 °C and at humidity levels ranging from 50 % to 90 % and 100 %.

OTR analyser

The OX-TRAN 2/12 can measure the oxygen transmission rates (OTR) of foils, coated papers and other smooth materials.  Its test cartridges are compatible with our water vapour analyser and provide gas-flushed perimeter sealing (TruSeal) that makes it possible to conduct precise and highly accurate tests ranging from 0.05 cm²/(m² d) to 28,800 cm²/(m² d) (without masking). The fully automatic temperature, flow and FH controls enable measurements to be taken between 10 °C and 40 °C and at humidity levels ranging from 0 % to 90 %.

Overview

The products lab has extensive analytical equipment. This enables both substance-specific and basic chemical-physical analyses of foodstuffs in liquid and solid form.

Rheometer

The laboratory is equipped with a rheometer for measuring rotation and oscillation to examine the flow behaviour and texture of products and determine their viscose or elastic characteristics. Tempering and sample-specific measuring systems (e.g. cylinder, double-gap, cone-and-plate or parallel-plate system) enable a wide range of examinations.

Particle-sizing device

This instrument is used to measure particles via laser diffraction with a wet dispersing unit for measuring e.g. suspensions, emulsions or dispersed solids. The measurement range is 0.01 to 3,800 μm, and evaluations can be conducted using either the Fraunhofer or Mie theory.

MilkoScan

For analysing milk and liquid or semi-liquid dairy products, our MilkoScan generates fast and accurate results using FTIR technology (after calibration) to ascertain the levels of constituent components such as protein, fat, free fatty acids, lactose, dry matter, etc. The resulting measurements can be combined with a sensory evaluation to draw conclusions regarding the shelf life and limiting factors. The resulting measurements can be combined with a sensory evaluation to draw conclusions regarding the shelf life and limiting factors. 

Overview

The sensory lab is equipped for preparing and conducting sensory tastings, but also for physical studies on food. Human sensory analysis can be supplemented, for example, with mechanical texture analyses and colour measurements. 

Human senses

The Sensory Laboratory has modular sensory booths for professional sampling. As KLEVERTEC conducts training on-site, we can take account of customers’ specific requirements. Furthermore, the products to be tested can be prepared/composed in a closed-off area.

Materials testing machine

Measurements can be taken to examine foodstuffs (e.g. textural analysis) and test materials (e.g. foils and other packaging).

The materials testing machine (max. 2.5 kN) can evaluate tension, compression, shearing and flexing. We can use various force transducers and measuring systems to examine samples with different properties and measurement sensitivities.

Colorimeter

The Sensory Laboratory has a DigiEye for conducting optical examinations / taking digital colour measurements. The sealed chamber with controlled lighting conditions and a high-resolution camera combined with colour calibration are used to take accurate, non-destructive, contactless measurements of samples. In the same manner, we can detect changes in colour throughout storage under different conditions (e.g. temperature, moisture, light) and identify factors that limit shelf life. In the same manner, we can detect changes in colour throughout storage under different conditions (e.g. temperature, moisture, light) and identify factors that limit shelf life.