Artificial vision has brought about a revolution in the industrial sector, with a huge impact on a range of industries, including drinks packaging. Artificial vision in drinks combines the use of high-resolution cameras with sophisticated software, allowing drinks companies to completely improve their production processes, thereby guaranteeing excellent product quality. Over the course of this post which we have drawn up at E2M COUTH, we will explain all the key reasons why such systems are vital in drinks packaging quality control.
The implementation of artificial vision in drinks packaging is transforming the way that companies ensure quality and efficiency on their production lines. This technology not only allows them to detect and correct defects automatically, but also improves traceability and production line efficiency, as well as reducing resource wastage. The capacity to inspect and monitor each step of the packaging process in real time allows products to fulfil the highest quality standards before they reach the end consumer.
What are E2M COUTH artificial vision systems?
Artificial vision is essentially a technology using advanced camera systems and fully specialised software to capture and analyse images in real time. This technology allows the machines to “see” and “understand” their surroundings similar to the way a person would do, but with greater precision and speed. Artificial vision is used to automate inspection and quality control processes in a range of industries, improving efficiency and reducing the likelihood of human error.
Such systems fulfil different functions, such as inspection, orientation or product rejection within a production line. These are the main components seen in quality control systems in the drinks sector:
- Cameras: The devices responsible for high-resolution imaging of the products within a production line.
- Lighting: This part of the system has the task of ensuring that the images are always clear and consistent, eliminating any shadows or reflections which could affect the image analysis.
- Image processors: Next, the processor sets about analysing the images captured, using advanced algorithms that are capable of detecting defects, measuring dimensions, and checking product conformity.
- Software: This has the task of fully coordinating the whole system, providing interfaces for configuration, monitoring and inspection parameter adjustment.
- Communication interface: Lastly, this component connects the artificial vision system to other production line control systems, allowing automated decision-making in real time.
The benefits of artificial vision in drinks
Here we set out the main benefits you can obtain with quality control systems for drinks packaging:
Quality control in drinks packaging
Artificial vision has completely transformed quality control in drinks packaging, as a fast and precise tool to detect defects. Artificial vision systems are capable of inspecting each container in great detail, identifying problems such as incorrect filling levels, poorly positioned labels, faulty caps and inappropriate closures. These systems allow:
- Fast defect detection: Defects are identified in real time, allowing for immediate correction, and preventing faulty products from reaching the consumer.
- Constant quality: They ensure that each product fulfils the established quality standards, providing consumers with a uniform experience.
- Documentation and analysis: The data recorded during inspections will be stored and analysed to identify patterns and areas for improvement in the production process.
Efficiency in drinks production lines
The implementation of artificial vision systems in drinks and their production lines considerably increases operational efficiency. This can be achieved by means of:
- Increased inspection speed: Artificial vision systems can perform inspections much faster than manual methods, allowing a fast, continuous flow of products on the production line.
- Precision and reduced human error: Automation minimises dependence on manual inspection, minimising human error and ensuring constant precision.
- Continuous monitoring: The capacity to conduct constant, real-time inspections helps to maintain quality and efficiency throughout production, automatically adjusting the parameters when deviations are detected.
Traceability in drinks
Traceability in drinks is another key aspect in the drinks industry, where artificial vision can facilitate the process in various ways:
- Product tracking: Artificial vision systems can read and verify barcodes, QR codes and other forms of packaging ID, ensuring that each product can be traced throughout the supply chain.
- Precise documentation: By maintaining detailed records of each inspection and production process, companies can swiftly trace any problem to its source and adopt effective corrective measures.
- Regulatory Compliance: The capacity to provide a full and verifiable history for each production batch helps companies to comply with quality standards and regulations.
Reduced wastage
Artificial vision can also help reduce the wastage which occurs in drinks production:
- Reduced errors: Detecting and correcting defects in real time reduces the amount of products that need to be rejected or reprocessed.
- Resource optimisation: Precise inspection ensures that materials and resources are used appropriately, avoiding excessive or insufficient use.
- Sustainability: Less wastage means a lower environmental impact, contributing to the company’s sustainability initiatives.
- Cost savings: Reduced wastage and improved use of resources means lower operating costs, thereby increasing production profitability.
Specific applications of artificial vision systems in drinks packaging
Here we set out the different uses and applications offered by the artificial vision systems we have available at E2M COUTH:
Filling level inspection
Guaranteed consistency in the amount of liquid in each container is very important, both to fulfil quality standards and to meet consumer expectations. A change in the filling level could lead to complaints and a loss of customer trust, as well as regulatory problems.
These systems use high-resolution cameras and sensors, which have the task of precisely measuring the filling levels of each container. These systems can:
- Capture images in real time: The cameras take images of the contents of each container as it moves along the production line.
- Image analysis: Advanced software has the task of analysing the images, so as to determine the filling level.
- Detection of inconsistencies: It also serves to identify filling levels that do not meet the established parameters, marking them for inspection or rejection.
Inspection systems are vital on any modern production line aiming to compete on the market.
Inspection of caps and labels
Checking the proper sealing and placement of caps is vital to ensure product quality and safety. A poorly positioned cap could cause problems such as spillage, contamination and product deterioration. With regard to caps:
- Seal inspection: Artificial vision checks that each cap is properly sealed.
- Proper placement: The system detects whether the cap is off-centre or poorly positioned, activating correction or rejection mechanisms.
As for labels, it is also important to ensure that they are properly applied and legible, in order to comply with the regulations and ensure consumer satisfaction. These labels offer vital information about the product, such as the ingredients, expiry date and barcode:
- Label position: Checking that the labels are uniformly applied and in the correct position.
- Legibility: Ensuring that the text and codes on the labels are legible and error-free.
If the proper labelling is not present or the label is not properly positioned, our rejection system will have the task of removing it from the production line. It should nonetheless be stated that this rejection may occur in different forms, either complete rejection, to remove it from the production line and discard it, or otherwise rejection by diversion, which will simply switch the product to another parallel line, for subsequent analysis.
Traceability in drinks
Product traceability refers to the capacity to track each product unit throughout the supply chain, from production to the end consumer. It is very important for quality management that problems are resolved and regulations fulfilled.
- Code reading: Cameras scan the codes on each container and register them in a database.
- Data verification: The software checks that the codes are correct and are linked to the right batch information.
- Records and tracking: The data from each container are stored to allow tracking and retrieval of information if necessary.
Double-closure systems on cans and bottles
Double-closure systems are very important to ensure that cans and bottles are hermetically sealed, preventing air and contaminant elements from entering.
In this regard, such systems check:
- Closure inspection: Artificial vision verifies that both closures are properly applied and are hermetic.
- Defect detection: The system identifies faulty or incomplete closures, and activates rejection mechanisms to prevent unsafe products from reaching the consumer.
In this regard, double-closure systems on cans and bottles offer various benefits:
- Prevention of contamination: Hermetic closures prevent contaminants from entering, ensuring product safety.
- Ensure freshness: They maintain product freshness and quality by avoiding oxidation and the loss of carbonation in fizzy drinks.
Container orientation
Proper orientation of the containers on the production line is vital for precise labelling and appropriate filling. A poorly oriented container may cause errors in these processes, leading to faulty products.
The orientation systems we offer at E2M COUTH are capable of identifying and correcting container orientation automatically:
- Orientation detection: The cameras capture images of the containers, while the software is responsible for analysing their orientation.
- Automatic correction: The systems adjust the position of the containers in real time to ensure that they are properly aligned before they move on to the subsequent production stages.
Find the best systems for drinks packaging quality control at E2M COUTH
At E2M COUTH we have a wide range of artificial vision solutions for drinks, which are particularly important in ensuring that your production is fully correct, preventing any faulty goods from coming into the hands of consumers. We also have a great many other particularly important artificial vision solutions available, such as orientation, inspection or rejection, which can be applied to the drinks sector along with many others. These are currently essential in order to compete on today’s market.
Want to know more about our artificial vision systems for use on different production lines? Get in touch now and we will offer you the very best advice.
