Accurate Label Inspection [Success Story]

Accurate Label Inspection Image

iVu Series vision sensors inspect plastic bottles conveyed on a production line, looking for misplaced labels. The remote touchscreen displays image results and provides an intuitive user interface.

Customer Requirements: Label inspection on heavy-duty plastic bottles

Solution: iVu Series vision sensor with optional remote touch screen

Why Banner? Ease of use—the iVu Series vision sensor takes the complexity out of the customer’s application; it’s a simple-to-use and easy-to-install solution that enables remote access to the user interface

Customer Benefits

Improved quality control—the iVu quickly and reliably detects missing, skewed and double labels on bottles, ensuring customers receive quality products

Resource savings—the customer was able to identify labeling issues early on and make corrections to the system, resulting in fewer bottles being scrapped

Background

An Ohio-based company produces heavy-duty plastic bottles for brands ranging from liquid laundry detergent and soft drinks to car care and lifestyle products. Product labeling is just one process that is fulfilled in their facility.

Challenges

The company was experiencing several quality control issues—bottles were coming off the line with missing, skewed and double labels. As a result, the customer was scrapping over 2,000 bottles a month, a process which requires them to cut out the mislabeled portion of the bottles and re-grind the plastic for reuse. Further, the labeling errors began prompting serious customer complaints. To avoid scrapping additional bottles and losing loyal customers, the company came to Banner for a label inspection solution.

Solution

Banner installed two iVu Series vision sensors per line at the customer’s facility. This makes it possible to reliably inspect labeling on the front and back of various bottle types. Using the Match tool, the customer can automatically verify that a specific label pattern, shape, or part matches a reference pattern, regardless of orientation. The cameras can identify and sort up to ten unique products within a single inspection. When a bad label is detected, the part is pushed off the conveyor into a scrap bin.

With the easy-to-use touch screen interaction, the customer was able to set up the cameras in a matter of seconds, and the optional remote display is an ideal solution for hard-to-access cameras on the line—users can see inspection images and access the user interface from the non-integrated display. With the iVu solution, the customer can quickly and easily detect missing, skewed and double labels in real time, eliminating complaints and reducing the number of bottles scrapped.

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