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Deficient quality control is a primary reason for product recalls in the Consumer Packaged Goods (CPG) industry. On an average, businesses lose approximately $10 million in revenue in direct costs and an unaccountable value via brand image and potential sales losses. Replacing legacy quality control systems, particularly inspection systems with foremost smart machine vision technologies, has been critical in mitigating such product recalls.
Leveraging machine vision, packaged goods manufacturers are minimizing operational costs and eliminating human errors. A typical machine vision system employs continuous image-based analysis to inspect packaging—increasing both output and revenue.
Problem:
The client’s legacy packaging inspection systems required manual intervention resulting in operational inefficiencies.
Objective:
While the client wanted to upgrade to newer packaging inspection systems, they also wanted an easily reconfigurable solution for other packaging lines that could also operate optimally in low light conditions.
Challenge:
L&T Technology Services (LTTS) engineers had to design a smart machine vision system that was modular, reconfigurable for other packaging lines, and operate optimally in low light conditions.
Process – Utilize Smart Machine Vision System:
The LTTS’ smart machine vision inspection system was built using modular components. These included high-resolution smart cameras with liquid lenses capable of changing focus rapidly and adjusting to different light levels and product types. LTTS’s solution enabled:
- Detection and rejection of defective packages
- Remote monitoring and data analytics for better visibility across the quality control process
- Integration of clean-in-place and sterilization-in-place (CIP/SIP) systems in LTTS’s equipment to maintain high standards of safety and hygiene.
- Verification of seals, caps, labels, bar codes, and batches
Highlight:
L&T Technology Services (LTTS) designed a cost-effective automated inspection and defect identification solution that could process as many as 160 bags per minute while rejecting damaged packages from the vertical form fill and seal (VFFS) machine. The machine vision inspection system uses multiple 2D/3D cameras, along with thermal and infrared sensors. This enabled the automation of packaging inspection and seamless classification and segregation of goods.
Results:
- Cost of Ownership - Optimized total cost of ownership by replacing the cost-intensive, legacy camera inspection system
- Leakage Detection - Enabled leakage detection for orifices with diameters smaller than 1mm
- Automatic Transfer - Facilitated automatic transfer of packaged good from VFFS to case packer