Vision system
for quality control of wet wipes packaging
Informacje
- Wyzwanie: web control
- Sektor: packaging
- Korzyść: increase product quality
- Technologia:
Solution
Find out how we solved the problem using our vision systems
The culmination of a thoughtful production process is the delivery of a defect-free product. Bringing only the highest quality products to the market enhances brand prestige and confidence. In order to achieve high final product quality, the production line must be equipped with quality control systems located at strategic points. In the case of wet wipes, proper packaging is particularly important.
The packaging industry is generally not associated with high quality control requirements or the use of the latest technology. Nothing could be further from the truth. Tests carried out by Scanway engineers have shown that the use of the highest quality 3D imaging is essential for quality control in packaging production.
Description of implementation
Find out exactly what implementation we have put in place at the client.
What do we control with machine vision?
The task the Scanway team faced was to propose vision systems capable of controlling:
- quality of the incision of the packaging film at the point of opening;
- the correctness of the sticker and the shape of the transparent closure label;
- legibility, correctness and position of the imprint containing key product data (date of manufacture, LOT number).
The first two points are crucial, as any leak in the packaging compromises the quality of the product: the wipes dry out, thus failing to perform their function. On the other hand, information on the LOT number and the date of manufacture is essential for tracking and managing the product ‘life’ cycle from manufacture to sale to disposal.
Challenges and technologies used
The first difficulty that had to be faced was the inspection of a web object. The characteristics of this type of production process imply the need for continuous inspection at high movement speeds of the object under inspection. The issues of positioning the vision system, appropriate lighting, triggering the image acquisition and processing the image at the appropriate speed in the case of packaging web inspection are among the most complex.
Inspection of the perforation cut and the opening sticker required the highest quality 3D imaging. It should allow measurements to be taken with micrometric accuracy despite changes in packaging web tension, vibrations, the influence of external lighting and other environmental factors.
2D imaging was used to test the reading of the print. Due to the characteristics of the production process, as well as the variability of the font colour. At the same time, the time for image processing was very limited due to the pace of production.
A separate challenge was the testing itself. The production process of web materials is extremely difficult to simulate under test conditions. At the same time, the high production throughput and quality requirements do not allow testing in a production environment. However, the knowledge and experience Scanway engineers gained in this and previous projects make it possible to measure up to such challenges.
Benefits of vision-based packaging quality control
The use of advanced technology in quality control of packaging offers many advantages:
- Increase the quality of the final product reaching the market, thereby achieving an increase in the level of trust in the brand.
- Reduce product damage from leaks (wipes will not dry out, they will remain damp).
- Improve the efficiency of product tracking in the production process.
- Increase control over the product life cycle which translates into multiple benefits in the distribution and recycling process.
- Increased automation in production providing the opportunity to increase line efficiency and product quality.
Summary
The tests carried out by Scanway provided a better understanding and definition of the challenges faced by machine vision when inspecting web material and the packaging production process in general. Experience in implementing similar systems and expert knowledge of hardware, and image processing algorithms were invaluable for carrying out these tests and obtaining meaningful results. Despite the very high difficulty of the task described, it is mostly feasible with the highest quality imaging and advanced algorithms.
Our solutions
Modular vision systems designed for quality control in industrial environments.
CUMULUS
A group of static vision systems designed for quality inspection
of individual objects moving at high speed along a production line.
Each item is subjected to real-time image analysis,
enabling precise verification of compliance with process requirements.
STRATUS
STRATUS is a group of stationary vision systems designed for the inspection of continuous raw material.
The systems analyze the web across its entire width, ensuring full real-time quality control.
The raw material moves at high speed along the production conveyor, while the systems remain stationary.
NIMBUS
NIMBUS is a group of advanced vision systems designed for the analysis of stationary objects, with the capability for system mobility. These solutions are dedicated for integration with robotic applications, including those operating outside the production line.
CIRRUS
CIRRUS is a group of vision systems designed to assess objects moving chaotically across large areas.
The systems analyze and predict changes in the observed terrain, finding applications primarily in satellite image analysis.
