Ensure the integrity of your packaging, from the initial audit through to staff training.
In high-demand industries, the performance of a packaging line does not depend solely on the purchase of a machine.
It requires rigorous support.
Control Sensei provides you with comprehensive expertise to diagnose deviations, validate your choice of materials and ensure the long-term viability of your quality control processes.
A comprehensive approach to aligning industrial performance with regulatory requirements.
In light of changing health (CCIT) and environmental (the European PPWR regulation requiring 100% recyclable packaging by 2030) regulations, Quality, R&D and Production departments must rethink their practices.
Our mission is to guide you every step of the way to place quality control at the heart of your operational profitability.
Discover how our four-fold expertise safeguards your value chain.
From diagnosis to recommendations and machine installation: Control Sensei supports you in four key areas, over the long term
1. ADVICE AND DIAGNOSIS
- Your teams are focused on production and meeting production targets. Identifying and preventing a micro-leak or deviation sometimes requires taking a step back.
- We work directly on your production lines to audit your heat-sealing parameters, analyse the mechanical behaviour of your films and map your risks of non-compliance.
Find out more about our areas of expertise:
- Machine drift audits
- PPWR transition support
- Optimisation of sealing rates
- Leak testing
2. PACKAGING TESTING AND QUALIFICATION LABORATORY
Don’t take any risks before launching a new batch or new packaging.
Our testing laboratory (and our network of partner technical centres, such as the CTCPA) scientifically validates the strength and leak-tightness of your containers.
- We define your sealing windows and test your samples under real-world physical stresses (pressure, vacuum, altitude simulation).
Find out more about our laboratory testing protocols:
- Leak testing: bubble test.
- Vacuum packaging qualification
- Dye penetration tests (methylene blue)
- Permeability measurement
3. SOURCING AND INTEGRATION OF QUALITY CONTROL EQUIPMENT
Depending on your sector, throughput rates and budget, we source or co-design with you the integrity monitoring technology that is perfectly suited to your IT and industrial infrastructure.
Because a test machine is of no use if it cannot communicate with your servers, I integrate your equipment whilst adhering to both your physical constraints AND your IT requirements (CFR 21 Part 11, Audit Trail, etc.).
If required, we install and qualify your equipment directly at your production sites, following strict IQ/OQ protocols.
Non-destructive solutions (focus on ROI and CSR)
- Your best tool for reducing waste and maximising ROI.
- Ideal for testing up to 100 per cent of production without any material wastage.
- Integration of vacuum decay/drop or gas analysis technologies (micro-leaks down to 10 microns).
Discover the solutions:
- WITT Leak Master Contura S-Series range
- ASC Instruments range
- WITT GAS systems for modified atmosphere packaging (MAP)
Standardised destructive testing methods
- The industry’s essential standards for the precise visual localisation of breaches, in compliance with strict regulatory requirements.
Discover our expertise in standards and guidelines:
- DVACI vacuum chambers and leak testers
- Protocols in accordance with ASTM standards:
4. ON-THE-JOB TRAINING AND SKILLS TRANSFER
- A technique is only valuable if it is understood by the teams.
- Control Sensei passes on its expertise directly to your operators and quality technicians, enabling them to work completely independently.
- We don’t deal in academic theory: we train your teams on your own equipment, taking into account your specific workflow constraints.
Our skills development themes:
- Master’s Degree in the Physics of Vacuum Technologies
- Interpreting leakage rates and false positives
- Preventive maintenance procedures
Move from technical validation to optimising your production lines
Whether you need to test the feasibility of a new single-material solution in our laboratory, re-configure your heat-sealing rates or implement an FDA-compliant audit trail, your challenges require bespoke solutions and unwavering trust.
Tell us about your industrial requirements and let Control Sensei design your ideal control architecture.