Auto-Trainable Vision System Ensures Quality for Future Product Combinations

EPIC Systems developed advanced auto-trainable vision system for a prominent Food & Beverage company that significantly improved quality control, reduced operational risks, and enhanced customer’s ability to introduce new products quickly and efficiently.

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Hygienic Process System Design

Project

Overview

  • Industry: Food & Beverage
  • Company Size: $1 billion – $5 billion
  • Location: USA
  • Customer Use Case: High-Speed Label Inspection, Optical Character Verification (OCV) 

Customer’s

Challenge

A leading Food & Beverage company faced a critical need to inspect both the front and back labels of bottled products on a high-speed filling line. The company needed a robust vision inspection solution to address three primary challenges: 

  • Risk of Recall & Market Share Loss: Misdated, miscoded, or mislabeled products could lead to costly recalls and loss of consumer trust. 
  • Frequent Product Changes: A competitive market required the frequent introduction of new product mix, necessitating rapid adaptation of labeling and coding. 
  • High-Speed Accuracy: The filling line operated at high speed, filling hundreds of bottles per minute, which posed a significant challenge for maintaining accuracy in label and code verification. 

Epic

Solution

EPIC Systems designed and implemented a custom vision inspection system to ensure high-speed, high-accuracy label and code verification. The solution incorporated: 

  • Front and Back Label Inspection with advanced recipe and label verification to confirm correct artwork and product details. 
  • Date and Lot Code Inspection using Optical Character Verification (OCV) to check quality, contrast, and legibility of printed codes. 
  • Auto-Trainable Vision System, enabling line operators to quickly add and verify new product combinations without requiring extensive programming or technical expertise. 

The system’s training mode allowed operators to run the first ten (10) products of a new batch through the inspection station, automatically teaching the vision software the correct label, artwork, and code placement. Once trained, the system resumed full-speed operation, ensuring consistent and precise inspection of hundreds of bottles per minute. 

Project

Impact

  • Enhanced Quality Control & Compliance: Prevented mislabeled or miscoded products from reaching consumers, reducing recall risks and ensuring regulatory compliance. 
  • Increased Operational Efficiency: The auto-trainable feature reduced downtime when introducing new products, accelerating product changeovers. 
  • Improved Production Throughput: The high-speed inspection system maintained accuracy without slowing down the filling line, optimizing productivity. 
  • Greater Market Agility: The ability to quickly add new product variations allowed the company to respond faster to changing consumer preferences and market trends. 

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EPIC Systems is a multidisciplinary engineering integrator specialized in industrial automation for process manufacturers. We deliver solutions in the following areas:

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