Automated Detergent Pack Leak Inspection

EPIC Systems automated vision inspection system addressed the customer’s challenge of detecting leaks in unit dose detergent packs. The solution provided long-term benefits ensuring efficiency, accuracy, and product quality while achieving 99.99% accuracy.  

Hygienic Process System Design

Project

Overview

  • Industry: Consumer Goods
  • Company Size: Fortune 500
  • Location: USA
  • Customer Use Case: Damage and Defect Inspection

Customer’s

Challenge

A multinational consumer goods company faced significant hurdles in their quality control process, struggling to detect minuscule and sometimes delayed leaks in detergent packs. Traditional visual inspections were inadequate, leading to substantial production inefficiencies. These undetected leaks resulted in costly downtime and waste, as defective products would contaminate hoppers and production lines, requiring extensive cleaning and halting operations. 

Epic

Solution

To address the customer’s inspection challenges, EPIC Systems devised a system that replaced manual inspection with a fully automated system. First, a specialized roller mechanism was introduced to exaggerate any potential holes or defects in the packs, which often went unnoticed. This allowed for the identification of even the smallest defects that might not immediately leak. 

Following this, the compressed packs were subjected to an innovative vision inspection system that utilized UV light techniques. The techniques ensured that any leaks were made visible, causing them to glow.  Additionally, Cognex In-Sight 5600 cameras captured the images of the packs, allowing for the accurate detection of defects.  

An HMI screen displayed the detected leaks, providing real-time feedback to operators. This interface allowed personnel to adjust the system as needed, ensuring optimal performance and accuracy. 

 Any packs identified as defective were automatically removed from the production line before they could cause downstream contamination. This ensured that only high-quality products progressed further in the manufacturing process. 

 

Project

Impact

  • Operational Efficiency: With the capability to inspect packs at a line 15 feet per minute speed, the system ensures high-speed, accurate quality control. 
  • Enhanced Accuracy: The system achieved a product accuracy of 99.99%, surpassing the client’s expectations and significantly reducing the risk of undetected leaks. 
  • Elimination of Downstream Contamination: By removing defective packs before they could contaminate production lines, the system prevented downtime and waste, leading to increased operational efficiency. 
  • Streamlined Inspection Process: The automation of quality control processes eliminated the need for tedious manual inspection, reducing labor costs and minimizing human error. 

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Our Solutions

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

Process Systems

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Machine Vision

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Robotics

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Industrial Automation

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