Heat Seal Tester Heat Seal Test System
Features of Heat Seal Tester
Powered by Yamaha's Sound Expertise ULTRASONICA®
Heat seal defects such as internal delamination and air bubbles cannot be detected by visual or camera inspection, while conventional sampling and destructive testing fail to ensure full quality assurance-leaving a constant risk of market recalls and brand damage.
Against this backdrop, ULTRASONICA® -an ultrasonic camera from Yamaha's sound expertise-was created.
Proprietary airborne ultrasonic sensors and acoustic signal processing enable visualization of the internal condition of heat seals, allowing for non-destructive, non-contact, in-line 100% automated inspection.
Quantify and visualize seal quality to enable truly objective inspection, clarify release criteria, and reduce the risk of defects reaching the market. With traceable data, ULTRASONICA® enhances audit readiness and quality accountability.
Against this backdrop, ULTRASONICA® -an ultrasonic camera from Yamaha's sound expertise-was created.
Proprietary airborne ultrasonic sensors and acoustic signal processing enable visualization of the internal condition of heat seals, allowing for non-destructive, non-contact, in-line 100% automated inspection.
Quantify and visualize seal quality to enable truly objective inspection, clarify release criteria, and reduce the risk of defects reaching the market. With traceable data, ULTRASONICA® enhances audit readiness and quality accountability.
Defect Escape Prevention
Accuracy
Industry-first ultrasonic heat seal inspection with a line sensor. Powered by Yamaha's acoustic signal processing, it achieves exceptional sensitivity and visualizes previously undetectable defects-regardless of packaging color or material. Non-destructive, non-contact, in-line 100% automated inspection prevents defect escape.
Innovative Ultrasonic Camera
Intelligent Judgment Function
Stability
ULTRASONICA® features up to six inspection judgment functions, tailored to packaging types and product specifications, enable flexible detection of various seal defects. Combined multi-judgement functions suppress false positives, preventing unnecessary rejects and yield loss. With conveyor speeds of up to 60 m/min, it ensures stable quality control and efficient production even on high-speed lines.
Flexible Judgment Functions
Image-Based Quality Assurance
Reliability
Ultrasonic technology clearly visualizes seal conditions as images, enabling intuitive identification of defect location, size, and shape-previously detected only through numerical data or graphs. All results are recorded as image data, ensuring full traceability. This supports robust quality assurance, builds customer trust, and enables root cause analysis and continuous improvement.
Visualization of Seal Quality
Visualizing Seal Conditions with Airborne Ultrasonic Technology
As packages pass through the ultrasonic sensor head, seal conditions up to 20 mm in width are visualized as images.
Using an inspection principle based on variations in ultrasonic signal intensity, it detects packaging defects that are difficult to identify visually including in aluminum laminates and printed films.
Using an inspection principle based on variations in ultrasonic signal intensity, it detects packaging defects that are difficult to identify visually including in aluminum laminates and printed films.
![[ Image ] Ultrasonic Sensor Head](./file/1198/heatsealtester_img27.jpg)
Ultrasonic Sensor Head
![[ Image ] Judgment Screen & Inspection Images](./file/1197/heatsealtester_img28.jpg)
Judgment Screen & Inspection Images
Easy Setup
- No specialized skills, experience, or certifications required
- Intuitive operation via touchscreen and user-friendly interface
- Easy recipe creation for configuring pass/fail criteria
![[ Image ] Easy Setup](./file/1056/heatsealtester_img05.jpg)
Flexible Installation
- Ultra-compact sensor fits into limited spaces
- High installation flexibility across various processes
- No major modifications required for layout changes
![[ Image ] Flexible Installation](./file/1223/heatsealtester_img06.jpg)
Stable Operation
- Reduced setup time contributes to stable production
- Low running costs with no periodic replacement parts
- Easy daily checks, setup, and maintenance
![[ Image ] Stable Operation](./file/1199/heatsealtester_img07.png)
Data Utilization
- All packages can be recorded as numerical data
- Supports predictive maintenance of production equipment
- Monitors daily and monthly defect counts and trends
![[ Image ] Data Utilization](./file/1059/heatsealtester_img08.jpg)
Defect Patterns
![[ Image ] Good](./file/1214/heatsealtester_img29.png)
![[ Image ] Incomplete Sealing](./file/1204/heatsealtester_img30.png)
![[ Image ] Wrinkles / Creases](./file/1217/heatsealtester_img31.png)
![[ Image ] Skewed / Misaligned](./file/1206/heatsealtester_img32.png)
![[ Image ] Fold-In](./file/1218/heatsealtester_img33.png)
![[ Image ] Pinholes](./file/1220/heatsealtester_img34.png)
![[ Image ] Insufficient Width](./file/1215/heatsealtester_img35.png)
![[ Image ] Double Feeding](./file/1212/heatsealtester_img36.png)
![[ Image ] Entrapment (Flour)](./file/1216/heatsealtester_img37.png)
![[ Image ] Entrapment (Bonito Flakes)](./file/1211/heatsealtester_img38.png)
![[ Image ] Entrapment (Nonwoven)](./file/1221/heatsealtester_img39.png)
![[ Image ] Over-Sealing](./file/1208/heatsealtester_img40.png)
Solution Cases
Supports Various Seal Positions and In-Machine Installation
Examples of Inspectable Packaging
Top Seal
![[ Image ] Top Seal](./file/1207/heatsealtester_img41.jpg)
Center Seal / Vertical Seal
![[ Image ] Center Seal / Vertical Seal](./file/1209/heatsealtester_img42.jpg)
Top Seal
![[ Image ] Top Seal](./file/1203/heatsealtester_img41sp.jpg)
Center Seal / Vertical Seal
![[ Image ] Center Seal / Vertical Seal](./file/1201/heatsealtester_img42sp.jpg)
Examples of Applicable Processes
Rotary Pouch Filling Machines
![[ Image ] Rotary Pouch Filling Machines](./file/1200/heatsealtester_img43.jpg)
Form-Fill-Seal Machines
![[ Image ] Form-Fill-Seal Machines](./file/1210/heatsealtester_img44.jpg)
Automatic Sealing Machine
![[ Image ] Automatic Sealing Machine](./file/1202/heatsealtester_img45.jpg)
Aligning Conveyor
![[ Image ] Aligning Conveyor](./file/1213/heatsealtester_img46.jpg)
Horizontal Form-Fill-Seal Machine
![[ Image ] Horizontal Form-Fill-Seal Machine](./file/1219/heatsealtester_img47.jpg)
Vertical Form-Fill-Seal Machine
![[ Image ] Vertical Form-Fill-Seal Machine](./file/1205/heatsealtester_img48.jpg)
Applicability by Packaging Type and Material
Inspection feasibility may vary depending on packaging specifications and conditions, even for the cases below as reference examples.
| Inspectable | Examples |
|---|---|
| Plastic Films / Laminated | Transparent, white opaque, printed, light-shielding, and colored pouches, etc. |
| Metal-Based High-Barrier | Aluminum vapor-deposited, foil laminates, transparent barrier pouches, etc. |
| Paper, Nonwoven, and Fibers | Eco-friendly paper, nonwoven and mono-layer paper pouches, etc. |
| Non-Inspectable | Examples |
|---|---|
| Multi-Layer / Multi-Seal | Top/end & center overlaps, gusseted pouches, kraft/PE double-layer bags, etc. |
| Formed or Rigid Containers | Spouted pouches, tray/cup seals, blister packs, thermoformed containers, etc. |
| Without Seal Areas | Shrink, sleeve, and skin packaging, etc. |
製品仕様
FAQ
- ULTRASONICA®では、どのようなシール不良を検出できますか？
- シール抜け、剥離、ピンホール、シワ、折れ込み、シール位置ズレ、二枚取り、粉や不織布などの噛み込み、過溶着、弱溶着などの検出に対応します。
ただし、検出可否や検出精度は、包材構成、シール幅、内容物、搬送状態、不良の大きさ・位置などによって異なります。実包材・実サンプルによる事前評価を推奨しています。 - 外観では見えにくいシール不良も検出できますか？
- はい。ULTRASONICA®は空中超音波を用いて、ヒートシール部の内部状態を画像化します。
目視検査では判断しにくいシール部の剥離や、粉噛み、弱溶着など、外観だけでは見落としやすい不良の検出をサポートします。 - 検査のために袋を開封したり、加圧したり、水に浸したりしますか？
- いいえ。ULTRASONICA®は、非破壊・非接触で検査する方式です。
製品を開封せず、包材に押し当てることなく、搬送中のヒートシール部を検査できます。検査後の商品をそのまま出荷工程へ流せるため、全数検査への展開にも適しています。 - どのような包材・包装形態に対応していますか？
- 樹脂フィルム、ラミネート包材、金属系ハイバリア包材、などのヒートシール部を対象に評価できます。
主に、トップシール、一辺シールの袋、横ピロー包装、縦ピロー包装などで導入・検証実績があります。多重シール、立体容器、シール部が存在しない包装形態などは、検査が難しい場合があります。 - 生産ライン上で全数検査できますか？
- はい。包装機やコンベヤーと連携し、製造ライン上での全数検査を想定したシステムです。
不良判定結果を排出装置や上位システムへ連携する構成にも対応可能です。実現可否は、袋の搬送姿勢、ピッチ、速度、検査対象辺、設置スペースなどを確認したうえでご提案します。 - 既存の包装ラインにも後付けできますか？
- ライン条件によっては、既存設備への後付け導入が可能です。
包装機の種類、搬送方向、シール部の位置、袋間隔、周辺装置との接続条件を確認し、最適な設置方法を検討します。包装機メーカーとの協業によるオプション設定の実績もあります。 - どの程度の小さな不良まで検出できますか？
- 検出可能な不良サイズは、包材、シール条件、不良の種類、センサーと袋の距離、搬送安定性などによって変動します。
G2センサーを用いた検証では、最小φ1.0mm程度の欠陥を確認した事例がありますが、すべての条件で同等の性能を保証するものではありません。対象ワークでの事前検証により、判定基準をご提案します。 - 検査結果は確認・保存できますか？
- はい。シール部の検査画像と判定結果を保存できます。
不良発生時の原因分析、製造条件の見直し、品質記録の保管、取引先への説明資料などに活用できます。保存件数やデータ連携方法は、システム構成に応じてご相談いただけます。 - 弱溶着やシール強度のばらつきにも活用できますか？
- はい。ULTRASONICA®は、単なる穴あきやシール抜けだけでなく、シール状態のばらつきを捉える用途にも活用されています。
引張強度試験などの既存評価と組み合わせ、超音波データとの相関を確認することで、弱溶着の早期検知や工程管理への応用が期待できます。 - 導入前に、自社の包材・不良サンプルで評価できますか？
- はい。実際にご使用の包材、良品・不良品サンプル、包装仕様をもとに、検査可否や検出傾向を確認できます。
「どの不良を検出したいか」「どの工程に設置したいか」を伺ったうえで、評価方法、必要な設備構成、導入イメージをご提案します。まずはお問い合わせください。
Sample Testing
Free Testing of Your Samples
For customers considering our inspection system, we offer free sample testing to evaluate inspection performance in advance. Detection accuracy varies depending on packaging format, materials, and sealing conditions, so we recommend prior evaluation using actual samples. By sending both good and defective samples, you will receive a sample test report confirming the detectability of seal defects.
Introduction Process
- Inquiry
- Requirements Review
- Sample Testing
- Delivery & Training
Eligible Product for the Japanese SME Labor-Saving Investment Subsidy
![[ Image ] Subsidy rate:up to 50%](./file/1222/heatsealtester_img49.png)
Winner of the Category Excellence Award at the JAPAN PACK AWARDS 2025.
![[ Image ] JAPAN PACK AWARDS 2025](./file/1181/heatsealtester_img50.png)
Contact point
Inquiry by email
Inquiry by phone
+81-53-467-3601