aVisBot - Solution for detecting label, cap, liquid level errors in the bottling industry

aVisBot is a series of advanced visual inspection systems that use artificial intelligence and machine vision technology from AVATECH to automatically detect defects on bottles and jars in the production of food, pharmaceuticals, and beverages. This system helps businesses improve product quality and optimize production processes.

aVisBot - Label, cap, liquid level inspection system in bottling industry

Highlights of aVisBot:

AI Integration: Using deep learning algorithms to identify and classify defects with high accuracy.

Comprehensive Inspection: Capable of 360-degree inspection, detecting visual defects of bottled products

High Speed: Meets the inspection needs in production lines at high speed without affecting performance.

Friendly Interface: Easy to integrate into existing systems and user-friendly, reducing training and deployment time.

aVisBot is designed with many different inspection stations, helping to ensure product quality comprehensively. These inspection stations operate synchronously, using computer vision technology and artificial intelligence to detect defects with high accuracy.

1- Lid inspection station

Detecting Cap Faults Using Color Cameras

Product cap faults can seriously affect the quality, safety and aesthetics of the product.

Product Leakage: Loose, distorted or unsealed caps can cause product leakage, affecting quality and causing waste. This is especially important for products such as beverages, cosmetics, pharmaceuticals or chemicals.

Contamination, reduced product shelf life: If the cap is not completely sealed, bacteria, air or moisture can enter the product, spoiling the product or reducing its effectiveness.

Loss of pressure or preservation gas: In the food and beverage industry, some products need to be stored under pressure or with CO₂ gas to maintain flavor and freshness. If the cap is faulty, this gas can escape, reducing product quality.

aVisBot uses 2-4 AI cameras to inspect 360° to detect all types of errors that occur with bottle caps during the filling process: no cap, channel/open cap, scratched/broken cap, cap foreign body, gap protection ring, cap type, 3-prong broken.

                                 

Detect errors in plastic caps, aluminum caps

2- Level inspection station

Faulty liquid levels in products can have many negative impacts on quality, user experience, and brand reputation.

Not ensuring enough standard capacity: If the liquid level is lower than the standard, the product does not meet technical requirements and may be complained or returned by customers. This is common in the food, beverage, cosmetics, and pharmaceutical industries.

Liquid Leakage or Spillage: If the liquid level is higher than the allowable level, the bottle cap or packaging may not be sealed, leading to leakage during transportation and storage. This reduces product quality and causes waste.

Affects Product Stability: In some industries such as pharmaceuticals or chemicals, incorrect liquid levels can affect the ingredient ratio, changing the effectiveness of the product.

The system uses 2 high-speed cameras to control the product flow to avoid shortage or excess when filling.

Liquid Level Check

3- Label Check Station

Product labels not only help identify the brand but also provide important information about ingredients, instructions for use, expiration date, etc. When the label is defective, it can negatively affect many aspects, from product quality to customer experience and business reputation.

Difficulty in product identification: If the label is defective or missing important information (ingredients, usage instructions, manufacturing date, expiry date, etc.), customers will have difficulty choosing and using the product.

Confusing or misunderstanding information: Incorrectly printed labels can mislead customers about the product's uses, ingredients, or instructions for use, leading to negative experiences or even harm to health (especially in food and pharmaceuticals).

Affecting purchasing decisions: Poor quality product labels can reduce customer trust, causing them to choose competitors' products instead of your brand.

The system uses 2 - 6 AI cameras to check for errors that occur with labels during the packaging process: no label, torn/peeled label, overlapping label, folded label, wrong/reverse/skewed label, checking print quality.

Double-sided label inspection

Depending on the characteristics of the customer's product, AVATECH will propose the most optimal solution, including choosing the appropriate equipment, specifications and quantity, to thoroughly solve the problem while still ensuring optimal cost. For example, for double-sided label products that do not require color inspection, only two mono cameras are needed to capture images of both sides. Meanwhile, for round label bottles, 3 to 6 cameras are needed to fully collect images of the entire product surface.

Round label inspection with color camera

In label inspection, another very important issue that needs to be considered is print quality. Errors such as color errors, missing prints, blurred prints, smudges, and incorrect information can directly affect the aesthetics and accuracy of the product. This is especially important for the food, pharmaceutical, and cosmetic industries, where label information such as expiration dates, ingredients, instructions for use, and barcodes need to be printed clearly and accurately.

To check print quality, aVisBot uses technologies such as high-resolution industrial cameras, advanced image processing algorithms, and specialized lighting to detect even the smallest errors. In addition, the integration of artificial intelligence (AI) helps the system automatically analyze and identify errors that are difficult to detect with the naked eye and improve accuracy during the inspection process.

Some errors that may arise due to the printing process include:

Color error: The color on the label is not true to the original design, possibly due to printer error or color mixing error.

Missing print: Part or all of the content on the label is missing, usually due to insufficient ink or clogged print head.

Blurred, blurred print: Images or text are blurred due to smudges of ink that have not dried yet, or because the label surface is not suitable for the type of ink.

Incorrect information: The content printed on the label is incorrect, such as incorrect production date, expiration date, ingredients, or barcode information that cannot be scanned.

Strict control of printing quality helps businesses avoid risks related to product information confusion, while enhancing brand reputation and ensuring compliance with product labeling regulations on the market.

Check print quality

4 - Date code inspection station

Date Code (production date code, expiry date) is an important information on the product, especially in the food, pharmaceutical, cosmetic and chemical industries. If the Date Code is faulty, it can cause many negative impacts, affecting customers, businesses and even legal regulations.

Using expired products: If the Date Code is printed incorrectly or blurred, customers may use expired products, causing serious health effects (especially for food, medicine, cosmetics).

Unable to determine the expiry date: If the Date Code is unreadable or missing, consumers will not know whether the product is still safe to use or not, increasing the risk of waste or causing harm when using.

The code and date reading system uses OCR, pattern matching, checking the quality and accuracy of the printed text: not printed, missing, incorrect, blurred, missing, wrong size of printed text.

Read the code, expiration date

5- Deformation inspection station

Deformation errors (shape, size, curvature, distortion, warping, etc.) can seriously affect the quality, safety and aesthetics of the product. In industries such as food, pharmaceuticals, packaging, mechanical components or industrial production, ensuring the correct contour is an important factor to maintain quality and brand reputation.

Product does not match other parts: In the mechanical and electronic industries, if a part has a deformation error (distortion, warping, wrong size), it may not be assembled correctly, causing system errors or reducing operating efficiency.

Affects durability: If the contour is not up to standard, the product may crack, break, or become unstable during use, reducing its lifespan.

Leakage or loss of protection: In the packaging or food industry, defects in the shape of bottle caps, boxes, or seals can cause loss of sealability, leading to leakage or reduced ability to preserve the product inside.

Check for form errors

Benefits of using aVisBot:

✅ Improve product quality: Detect defects early, reduce the rate of defective products reaching customers.

✅ Save costs: Reduce costs related to defective products and remanufacturing.

✅ Increase production efficiency: Automating the inspection process helps increase productivity and reduce dependence on labor.

With aVisBot, AVATECH continues to affirm its pioneering position in providing high-tech solutions, meeting the increasing needs of the manufacturing industry.