More insight. More safety.

Real-time data on breakage

A glass container breaks on the production line – but no one knows why! Situations like these are challenging for
bottlers: breakage points can be hard to detect, and causes often remain unclear. To support customers more effectively, Vetropack uses precise measurement systems that not only help identify the root causes of such issues but also proactively prevent them from occurring. 

Vetropack Austria has been successfully using the ShockQC inline sensor from the Canadian company Masitek. The system accurately records shock loads acting on a glass container during production. It operates using a replica of the original container – a plastic model fitted with a calibrated sensor. This setup delivers accurate, real-time data for analysis.

The sensor is located directly inside the original glass container

To further accelerate analysis for customers, Vetropack’s Technical Customer Service team is now adding a second system to its portfolio: a sensor that is installed directly in the actual glass container – no replicas, no delays. The system was developed in 2019 by the Institute for Glass and Raw Materials Technology (IGR) in Göttingen (Germany). 

IGR specialises in chemical and physical glass analysis. “We provide comprehensive support to the glass industry. Our goal is to truly understand why a glass container breaks on the production line,” explains Heiko Hartung, an expert at IGR. “To achieve this, we conducted an in-depth market analysis. In practice, the assumption is often that the line is simply running too fast. Speed is typically measured in inches per second (IPS). But we found this explanation too superficial. We wanted to identify exactly where forces are acting – and why they lead to breakage.” 

Provides fast results for effective decision-making

The IGR sensor consists of two modules that can be easily and securely mounted inside a glass bottle. This enables real loads to be measured at every point along the line – from the depalletiser to the packaging unit. The sensor is completely liquid-tight and can pass through the line multiple times without disrupting production. Data is recorded directly from within the bottle as precise raw values, enabling realistic, unfiltered evaluation. 

Michael Waltl from Technical Customer Service at Vetropack Austria highlights the practical benefits: “The greatest advantage of the new system is time. While projects using replicas previously took six to eight weeks, now we can often deliver usable results within just a few days using the new sensor.” 

The ShockQC sensor from Masitek and the new sensor system from IGR complement each other perfectly in terms of functionality. While ShockQC delivers highly precise measurements using a specially manufactured replica, the IGR sensor allows for flexible, short-term deployment directly in the original glass container – with minimal effort. “This gives our customers even more options for identifying critical loads on the line, addressing them effectively, and optimally adjusting their processes,” Waltl explains.

Field-proven sensor solutions

Initial feedback from the field has been positive. “Customer response to these types of sensor solutions is generally very strong,” says Waltl. “By combining both systems, we will be able to operate even more flexibly and efficiently in the future – depending on specific requirements, challenges, and product types.” The idea behind the new sensor system is not new, but its implementation is highly innovative. The search for a suitable solution at IGR began over six years ago. The system was market-ready before the pandemic and was then tested in real-world conditions with initial customers.

Collaboration with Vetropack has been practical and results-oriented from the very beginning. Cooperation began around a year and a half ago, following initial discussions with the Managing Director of IGR. A first joint test run was conducted shortly afterwards, including a direct comparison with the existing Masitek system. The first training course for Technical Customer Service took place in April 2025 – an important milestone for future applications in the field.

Proactive technology for early detection

A key advantage of the new sensor is that it can be passed through the line as often as needed, offering maximum flexibility – during live operation, directly in the original container, and under real production conditions. This enables straightforward, regular line audits and helps bottlers identify, document, and eliminate potential sources of stress or contamination at an early stage. 

The use of this technology aligns perfectly with the strategic direction of Vetropack‘s Technical Customer Service. “We don’t want to wait until complaints arise before we step in,” says Waltl. “Our goal is to detect and eliminate potential weak points in advance.” This proactive approach is especially crucial when working with lightweight glass bottles, which respond to mechanical stress differently than conventional containers. 

Line tests and precise measurements have become essential components of a robust service concept. With the combination of ShockQC and the IGR sensor system, Vetropack customers now have access to a broad and flexible toolset for reliably analysing mechanical stresses on the line. This enables them to benefit from practical insights, reduced costs, shorter project timelines – and ultimately, more efficient and sustainable filling line optimisation.