Automated Vision Inspection for Wet Dog Food Production

By integrating an automated vision inspection system, EPIC Systems enabled the customer to maintain high-speed, high-quality operations with minimal waste and downtime through a cost-effective and highly efficient solution to a persistent production challenge. 

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Hygienic Process System Design

Project

Overview

  • Industry: Pet Food
  • Customer: Fortune 500
  • Location: USA
  • Customer Use Case: Defects & Damages

Customer’s

Challenge

An international pet food manufacturer was experiencing significant production issues due to dented cans. During high-speed production, cans were becoming dented which caused them to get stuck in the conveyor system or labeling equipment. With a high-speed production, a single stuck can lead to a rapid pileup in single-file formation. Once the backlog reached an opening in the conveyor rail, hundreds of cans would spill onto the factory floor.  

This not only resulted in substantial product waste, as dented and dirty cans had to be discarded, but also caused operational disruptions and inefficiencies, leading to downtime and increased labor costs. 

Epic

Solution

EPIC Systems developed an advanced automated vision inspection solution to identify and reject deformed cans before they could create blockages. A high-speed camera inspection system was installed over the conveyor belt before the labeler, capturing an image of every can. The system measured the roundness of each can by analyzing the diameter at multiple segments, ensuring precise detection of any deformation.  

If a can was found to be out-of-round, it was immediately rejected by a strategically placed rejector next to the vision system. This proactive solution prevented problematic cans from advancing further along the production line, mitigating the risk of jams and pileups. 

Project

Impact

  • Elimination of Conveyor Blockages: The system prevented dented cans from reaching critical points in the production process, reducing unplanned downtime and ensuring smooth operation. 
  • Reduction in Product Waste: The manufacturer eliminated the costly issue of hundreds of cans spilling onto the floor, leading to substantial savings in raw materials and waste disposal. 
  • Increased Throughput and Efficiency: With fewer disruptions, the production line maintained a consistent flow, enhancing overall productivity. 
  • Improved Quality Control: The inspection system ensured that only properly formed cans made it through to labeling and packaging, enhancing product integrity and customer satisfaction. 

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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:

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