Customer Challenges

During the production process, the client faced several issues, including:

• Empty cans without product inside

• Deformed can openings during shaping and packaging

• Incorrectly printed production/expiration date

• Lack of a system for automatically and accurately removing defective products at high speed

To meet stringent product quality standards and synchronize with the factory's traceability system, the client required a comprehensive, high-speed inspection solution capable of stable 24/7 operation.

ETEK’s Solution

ETEK designed and integrated an automatic inspection system that includes a date code printer, sensors, industrial cameras, image processing software, and an air-jet rejection unit. This system enables accurate defect detection and automatic rejection of defective products right on the production line.

Inspection Process for Can Shape & Contents

1. Product Movement on Conveyor: Snack cans are continuously transported on a conveyor to the inspection area.

2. Sensor 1 Detects Product: Upon reaching the first inspection point, the sensor triggers a height measurement to check if the can contains a product.

3. Sensor 2 Activates Camera: The second sensor detects the can and activates an industrial camera to capture an image of the can’s opening for deformation inspection.

4. Analysis & Classification: Data from the sensors and camera are processed by software to classify products as either OK (pass) or NG (fail).

5. Defect Rejection: Cans identified as NG are automatically removed from the line using an air-jet system, ensuring no impact on the flow of qualified products.

Quy trình kiểm tra nội dung in trên lon: Date Code Inspection Process

1. When the product reaches the printing station, the Markem-Imaje printer prints production and expiration information.

2. The printer sends a trigger signal to the camera and transmits the printed data.

3. The camera captures an image, which is processed using OCR (Optical Character Recognition).

4. The system compares the OCR result with the printer’s data to determine OK/NG status.

5. Cans with incorrect print content are automatically removed using the air-jet rejection unit.

Results Achieved

After implementation, the automated quality inspection system delivered impressive results:

• Inspection Speed: Up to 250 cans per minute, meeting production demands.

• Accuracy: 100% accurate in detecting empty cans, deformed can openings, and incorrect or poor-quality prints.

• Full Automation: Eliminated human intervention in the inspection process, reducing errors and increasing efficiency.

• Cost Savings: Reduced labor costs and improved productivity.

• Improved Product Quality: Ensured that only high-quality products reach consumers.

Our Commitment to the Client

ETEK is committed to supporting our clients throughout the system implementation and operation process. With a team of experienced engineers, we offer 24/7 support to ensure stable and efficient system performance. We believe that timely and dedicated support is key to helping our clients achieve peace of mind in production, enhanced efficiency, and long-term sustainable growth.