Thermalpas field deployment (Taiwan) · Heavy Industry
Food packaging line: batch rejects down from 2.5% to 0.3%
Roller-type thermal sensors replace inaccurate thermocouples on printing and sealing rollers.
- 2.5% → 0.3%Batch reject rate
- $1.5M/yrPlant-reported returns avoided
- Roller-typeSpring-contact sensor
The problem
A food packaging line uses heated rollers to seal each package — too cold and the seal fails, leaks happen, and the entire batch is rejected. Conventional thermocouples can't sit on a rotating roller without being pulled around, so the readings drift, and the line compensates by overheating, which damages the packaging itself.
What was installed
A Thermalpas roller-type sensor — abrasion-resistant coating and a spring-loaded contact that rides the roller as it spins — replaced the thermocouples. Temperature uniformity was recorded along each roll of product, and any roll that drifted out of tolerance was flagged for review.
The outcome
At one food plant, the batch rejection rate dropped from 2.5% to 0.3% after installation, which the plant values at $1.5 million a year in avoided returns and rework. The quality manager can now answer 'how do you know?' with recorded data.
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