EPIC Systems approached the challenge by conducting Bottle Inspection Feasibility Testing in our Vision Lab to determine whether a reliable machine vision solution could detect crushed bottles across the full range of bottle types.
A test camera and lighting configuration were assembled to evaluate multiple inspection strategies. During this evaluation phase, EPIC vision specialists determined the optimal lighting setup, camera positioning, hardware requirements, pass/fail thresholds, and expected performance.
Testing confirmed that high-contrast backlighting combined with specialized light control film would provide the best image quality for detecting bottle shape and identifying different bottle materials.
- High-contrast backlighting to enhance bottle edge detection and improve visibility across varying materials
- Specialized light management techniques to collimate light and increase defect contrast
- An advanced smart camera system capable of high-speed image processing directly on the line
- Geometric pattern recognition tools to identify bottle shape variations and asymmetrical defects
- Vision software for system configuration and data collection, enabling real-time analysis and traceability
- Sensor-based triggering to capture images as bottles pass through the inspection point
- An integrated in-line reject mechanism to automatically remove damaged bottles before packaging
Once the system design was finalized and approved by the customer, EPIC completed mechanical and electrical design reviews and assembled the inspection system in its vision lab.
During operation, bottles pass in front of a backlight that creates a clear silhouette of the container. The system analyzes the contrast to determine bottle material:
- Black contrast indicates opaque bottles
- Gray contrast indicates frosted bottles
- Minimal contrast indicates transparent bottles
The PatMax tool then evaluates geometric characteristics such as bottle height, width, and symmetry. Each bottle image is processed directly inside the smart camera, and inspection data is transmitted to a custom database for comparison.
If the system detects abnormalities outside the defined process control limits—such as a crushed or misshapen bottle—the PLC activates the reject mechanism, removing the bottle before it reaches the packaging area.
The fully tested system was then installed on the customer’s existing bottle line with minimal disruption to operations.
