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A beverage manufacturer was experiencing issues with case packing orientation and count errors, which were resulting in customer complaints and machine downtime due to jams. Acquire Automation, an automation solutions and services provider headquartered in Fishers (Indianapolis), IN, developed a complete inspection system integrated to an existing case packer to solve these issues. The intuitive Human Machine Interface (HMI) and inspection system uses a Matrox Iris GT smart camera for imaging and tool algorithm execution. The solution was installed within the case packer to count and verify the orientation of 40- and 50-count cases of shrink-wrapped and non-shrink wrapped juice boxes. The system has been able to detect the following errors: box flap/tab up, crushed boxes/extra boxes/rotated boxes (result in crushing), missing boxes, splices, and damaged and floating trays.
| Beverage inspection system counts and verifies orientation of juice boxes |
| A complete packaging inspection system is integrated within an existing case packer to accurately count and verify the orientation of juice boxes. Source: Acquire Automation |
The system automatically saves failed inspection images for subsequent evaluation. The HMI provides log-in access control to prevent unauthorized personnel from altering the system, and includes detailed product counters for data collection and trend estimation.
| Intuitive, easy to use HMI |
| The operator interface shows the inspected image, and provides inspection controls and pass / fail statistics. Source: Acquire Automation |
The solution has received extremely positive feedback from the customer since it has resolved their packing orientation and count errors. The vision system not only works to identify product issues, but it also helps to quickly identify a process issue and, often, the root cause of the failure.
Acquire Automation is a Matrox Imaging Authorized Integrator who develops turn-key vision system constructed with the best components in the industry. The integrators enrolled in this program have delivered hundreds of vision systems to a wide range of manufacturing fields and disciplines from automotive to food, electronics to pharmaceuticals, medical devices to transportation, packaging to robotics. With years of combined experience, they have mastered the art of integrating vision systems with other automation systems and processes.