Gas analysers: Which one do I need?
Gas analysers have a variety of applications across several industries, including food, pharmaceuticals, and welding.
In the food industry, they are used to verify gas composition in modified atmosphere packaging (MAP) to extend product freshness and shelf life.
In pharmaceuticals, modified atmosphere is also used to prevent the oxidation and degradation of medicines and medical devices. This helps to retain the sterile atmosphere and maximum product efficacy for the entire shelf life of the product.
In welding, they ensure the correct gas blend is used for process stability and weld quality.
In this article, we help you choose the gas analyser that best fulfills your needs.
The EMCO gas analysers compared
Below, we compare our gas analysers based on key factors such as detection method, sensor type, accuracy, and industry-specific requirements.
Our devices range from economical handheld instruments for fast and easy spot checks to larger desktop units that perform semi-automatic sequential gas, leak, and burst tests.
All EMCO instruments collect measurement data via a companion USB or by connecting to your Wi-Fi network. Analysing this data over time can help streamline your packaging process.
GasCheck Handheld Gas Analyser
The GasCheck Handheld Gas Analyser is a portable and lightweight entry-level instrument best suited for quality assurance spot checks on modified atmosphere packaging production lines in the food industry.
While it’s the most economical gas analyser in our range, it offers fast and reliable measurements. It tests O2 only or O2 and CO2 with one-decimal precision and calculates the N2 balance inside a package.
The GasCheck Handheld also works exceptionally well for low-headspace applications - where the packaging contains minimal air. You can measure O2 in headspaces as little as 2ml and O2 and CO2 in headspaces as little as 6ml.
When should you choose the GasCheck Handheld?
For quick, on-the-go packaging quality assurance checks on food production lines and low-headspace applications.
BOX 120 USB O2 + CO2 Gas Analyser
The BOX 120 USB O2 + CO2 Gas Analyser is a desktop instrument. It’s an entry-level desktop device particularly suitable for the food industry.
It precisely measures O2 or O2 and CO2 (to one decimal place) and calculates the N2 balance in the package.
We call the BOX 120 our “workhorse” because it is robust, resilient to damage, and reliable.
We can integrate the BOX 120 with a rechargeable battery so you can also use it on the go. Based on the pump rate and timing between measurements, this supports 100 to 250 tests per charge.
Why should you choose a BOX 120?
The BOX 120 can operate 24/7 when plugged into the mains and offers many years of reliable use.
GasCheck Desktop Gas Analyser
The GasCheck Desktop Gas Analyser is a reliable, long-lasting desktop gas analyser with an integrated heater. It’s perfect for refrigerated factories and chilled packing facilities in the food industry, as the heater prevents condensation from forming inside the instrument, keeping the electronics safe from mould and water damage, and ensuring accurate measurements.
The GasCheck Desktop provides accurate O2 or O2 and CO2 measurements (to one decimal place) and determines a package's N2 content.
It can be specified with eletrochemical, optical, and zirconia oxygen sensors to suit all applications.
While it’s a desktop instrument, we can fit the GasCheck Desktop with a lithium-ion battery that lasts up to 250 measurements.
We produce two versions: one with a stainless steel housing and one with a portable but robust plastic carry case.
The stainless steel version is easy to clean and splash-proof, which makes it ideal for the meat industry.
Why should you choose the GasCheck Desktop?
It’s the best gas analyser for industries relying on cold storage facilities because it’s easy to clean, splash-proof, and has an internal heater.
Optical Gas Analyser - TPC Opti
EMCO’s Optical Gas Analyser - TPC Opti is a desktop instrument that measures the gas inside packaging with extremely small headspace, including vacuum packages.
The TPC Opti has a state-of-the-art optical oxygen sensor inside the needle. Without the need for a pump, it can measure oxygen inside vacuum headspace packaging in the pharmaceutical and food industries.
It provides precise O2 readings and calculates the packaging’s N2 content.
When should you choose the TPC Opti?
For analysing the gas content inside blister pill packs, milk powder sachets, coffee capsules, sauce sachets, and other low-headspace or vacuum packaging.
PMC Online Gas Analyser & Flow Optimiser
The PMC Online Gas Analyser And Flow Optimiser is a two-in-one gas analyser and flow optimiser for horizontal and vertical flow wrap packaging machines. It integrates into your packaging machine and pilots the gas flush facility.
The PMC features one needle and pump that measures O2, CO2, and N2 for packaging quality assurance spot checks. It also features a sniffer tube (which needs to be placed as close to the sealing jaws as possible) and a pump that continuously monitors N2 and/or CO2. This setup determines how much O2 is being successfully displaced by N2/CO2 when gas flushing.
If the O2 level rises above the configured threshold, the flow is immediately increased to bring it back down. The flow is then optimised to use the minimum amount of gas to achieve the desired gas levels.
You can customise the ramp-down speed to fine-tune efficiency, minimise gas waste, and cut costs.
The PMC is particularly suited for the food and pharmaceutical industries.
It has multiple sensor options, including electrochemical and optical, and its software allows you to program gas levels and flow rates.
Why should you choose the PMC?
It’s the only instrument that allows you to optimise your gas flow - leading to long-term gas savings - and fulfill your QC test requirements at the same time.
TPC Desktop - Gas + Leak + Burst Tester
The TPC Desktop is a package leak detector, gas analyser, and burst tester best suited for the food industry, particularly for products like coffee.
The TPC Desktop can be fitted with a wide range of sensor options, such as electrochemical, Zirconia, infrared, Ethylene, and more for exact measurements (to two decimal places). It performs accurate leak measurements, converting them to hole sizes down to 10 microns.
The burst function inflates the package until it bursts, enabling you to measure film strength and assess how packaging machine settings, like sealing temperature, seal depth, and dwell time, influence seal integrity.
For coffee packaging, the TPC can measure degassing valve performance - specifically flow rate, opening and closing pressures, and the seal integrity between the valve and film - using our custom stainless steel valve manifolds.
The TPC Desktop is also built in a 3-channel variant, which features multiple lanes and articulated arms equipped with a needle. This allows it to perform one-tap sequential gas, leak, and burst tests on multiple packages.
When should you choose the TPC Desktop?
For taking gas, leak, and burst tests on modified atmosphere packaging and streamlining your packaging process. It performs especially well with coffee packages when paired with these accessories: the DGV testing manifold, the 3 Way system, and high-flow filtered needles. These accessories are compatible with a range of products; contact us to find out if they’re right for yours.
If you’d like to learn more about the TPC Desktop and its accessories and available versions, read this article.
TPC Industrial - Automatic Gas + Leak + Burst Tester
The TPC Industrial combines leak detection, gas analysis, and burst testing. We designed it specifically for food products in pillow packaging, like crisps. However, it has been shown to work with various types of packaging. Contact us to see if it’s suitable for yours.
The TPC Industrial automatically inserts the needle using a pneumatic jack, eliminating the need for the operator to handle or replace it manually. This reduces the risk of injury and prevents needle blockage or damage. Additionally, its innovative needle with a silicone bellows design eliminates the need for septas.
The TPC Industrial can be fitted with a wide range of sensor options, such as zirconia, electrochemical, infrared, ethylene, and more for exact measurements (to two decimal places). It performs exact leak measurements that it converts into 10-micron hole sizes.
Finally, the burst tester function inflates the package until it bursts, allowing you to assess film strength and evaluate how different packaging machine settings - such as sealing temperature, seal depth, and dwell time - affect seal integrity.
We can manufacture the TPC Industrial in a Multi Pack version, which is equipped with a custom-built tray tailored to your packaging size. This setup accommodates up to 4 packs, each with its own needle and sensor, enabling simultaneous testing across all packs.
When should you choose the TPC Industrial or the TPC Multi-Pack?
For highly precise gas, leak, and burst testing on modified atmosphere packaging, for optimising your packaging process, or when you need a device that eliminates operator contact with the needle.
If you want to learn more about these instruments, head to this article.
GasCheck Ethylene
The GasCheck Ethylene is a portable, lightweight ripening control instrument that measures ethylene concentration in fresh produce in cold stores.
It can be equipped with a long probe that you can insert into a refrigeration unit without opening the door and a lithium-ion battery that lasts up to 250 measurements.
Why should you the GasCheck Ethylene?
For ripening control and cold storage room measurements in the food industry.
Why choose EMCO
At EMCO, we don’t just offer the most innovative and precise gas control instruments for modified atmosphere packaging quality assurance on the market.
We can provide you with a validation kit to test your EMCO instrument's accuracy as often as you like. We provide a recalibration service within 48 working hours or offer a loan instrument, free of charge, within mainland UK.
Two of the world's top manufacturers - one in coffee and one in crisps - use our machines in North America, Europe, and Asia. Both companies are worth over $100 billion and use our units at all their combined 75+ sites.
Many of our instruments can be custom-built to suit your company’s unique needs and regulations.
Before choosing a gas analyser, give us a call. We can provide you with detailed specs and help you decide which instrument best suits your needs.