Enhancing Lid and Artwork Verification for High-Speed Production Line

EPIC Systems designed and implemented a lid and artwork verification vision inspection solution for a F&B customer to achieve greater operational efficiency, improved product quality, and enhanced reliability in high-speed production.

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Hygienic Process System Design

Project

Overview

  • Industry: Food & Beverage
  • Customer: $1billion – $5 billion
  • Location: USA
  • Customer Use Case: Lid & Artwork Verification

Customer’s

Challenge

A prominent food and beverage (F&B) company required a robust vision inspection system to ensure the correct lid and artwork were applied to containers on a high-speed production line. The system needed to: 

  • Verify that each container had the correct lid to match its base. 
  • Detect and reject containers with skewed, double, or missing lids. 
  • Handle two different container sizes while maintaining an inspection rate of 400 containers per minute. 
  • Be easy to install and maintain with minimal manual adjustments. 

Epic

Solution

EPIC Systems designed and implemented an advanced vision inspection system tailored to the company’s requirements. Key components included: 

  • A Cognex camera with an auto-focusing lens, enabling seamless inspection of both container sizes without manual adjustments. 
  • A custom Human-Machine Interface (HMI) for intuitive control and real-time monitoring. 
  • A stainless-steel over-conveyor stand, providing durability and ease of integration into the existing production line. 
  • An integrated pneumatic rejection system that efficiently tracked and removed defective containers from the line, preventing downstream issues. 

The vision system ensured accurate barcode verification, allowing for the automatic removal of incorrectly labeled or unreadable products. This prevented line stops and jams caused by misidentified products. 

Additionally, changeovers between container sizes were streamlined with a single-button press on the HMI, triggering the auto-focusing lens to adjust without the need for mechanical realignment, significantly reducing downtime. 

Project

Impact

  • Drastic reduction in packaging errors: Ensured only correctly assembled products reached consumers. 
  • Elimination of line stops and jams: Accurate barcode verification and rejection of defective products reduced downtime.
  • Enhanced speed-to-market: The system kept up with the demanding 400 containers/minute production rate.
  • Seamless changeovers: The auto-focusing camera eliminated the need for mechanical adjustments, allowing operators to switch container sizes with a single button press. 

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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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