A simple bottle inspection grew into a larger quality control tool!
The injection-blown bottles were initially inspected for two common defects when processing clarified PP; ”bubbles” and “black specks”—carbonized contaminants. Using these specifications, METTLER TOLEDO CI-Vision recommended a five camera inspection system: one camera for the bottom of the bottle and four cameras for the perimeter of each bottle. This provided a total surface inspection far exceeding inspection accuracy of the human eye. When defects were detected the solution would automatically remove bottles from the line, eliminating customer complaints.
Once installed, the system performed exceeding well. With an easy to use interface and intuitive software, line operators took complete ownership of the system on the factory floor. Originally programmed for contamination inspection applications, the system began detecting certain molding process variations that were occurring outside of the usual bubble and black speck contaminants.
The manufacturer’s plant management team discovered these variations when the software began detecting and rejecting bottles with molding abnormalities. This led the plant management team to asking if the system could detect other specific potential defects. Using the system’s easy to navigate software to provide useful quality feedback, the management team was able to pinpoint where problem areas were occurring on the production line and control them. As each new variation was identified, inspection tools were added to the system software to ensure out of spec bottles is rejected.
Today, the bottle maker has recognized that the vision system they bought is not only more accurate than manual inspection, but it also has the ability to grow into a more flexible tool as new inspection needs arise.