Importance of AI-Based Vision Inspection system in the Packaging and Printing Industry

Manufacturing industry is highly dynamic and the first impression of the products and brands is their packaging. If a defect or mislabel is not noticed before reaching the customers, the outcomes can be disastrous.

Research shows that consumers form their first impression about products in only seven seconds. Can you imagine the possible results if your factory overlooked packaging and print defects? Such unnoticed defects may result in severe losses for your business, which makes inspection for quality control a crucial function.

Here are some common printing and packaging errors:

Missing Relevant & Crucial Information

The outer packaging must clearly show important information like manufacturing and expiry date. If this crucial information is missing or not clearly printed, it can severely impact the reliability of the products and brand.

Improper Prints, Colour, or Labels

Batch codes are important as these are used to maintain the product database and in determining product pricing. Incorrect or absent batch codes can result in inaccurate product placements and pricing, leading to costly mistakes.

Incorrect or Absent Batch Code

Large companies are very attentive to the printing, colours, and labels to retain their brand image. These defects may be missed when manufacturers adopt manual inspection for quality checks and control.

Other Defects

These include missing liner in closures, cracked or fractured cans or bodies, narrow heat seals, misshaped cartons, pouch fractures, uneven outer surfaces, air or stone bubbles within glass bottles, small scratches on the package, and many more.

Catch these Defects with AI Vision

Types of Packaging and Possible Defects-

Packaging Type	Critical defects	Major defects	Minor defects
Glass containers	Penetrating checks and cracks Contamination with dust, insects, other foreign matters Chipped or broken finish	Glass weight less than minimum specified Non-functional stretching bead Leaner is over standard norms	Wavy appearance Stones Uneven outer surfaces
Plastic packages	Breaks or cracks Thickness is below specified limits Rough cut off resulting in leaky closure	Below minimum weight Dimensions outside limits Leaner’s over standard norms	Streaky pigmentation due to inadequate binding
Closures	Crack in metal caps Missing liners Outside permissible stress cracking dimension	Loose or hanging liners Orange or rough pill surfaces Consumer-related faults	Scratches on the caps’ external surfaces
Metallic packages	Seals leakages Cracks on ends or body Contamination	Dents affecting closing efficacy Out of round at open ends	External scratches
Labels	Incorrect copy or size Tears and holes In stick together Missing colours	Rough weight edges	Loose bonding Improper label identification
Blister packages	Holes or cracks Wall thickness below specified norms	Embedded foreign particle Visual defects Discolouration	Drawing or mould lines
Cartons	Dimensions beyond tolerance limits Tears or holes	Scoff surfaces Ink spreading	Outer surface stains
Aluminium foil	Core damages Missing sealing layer	Width variations Poor resistance	Lamination scratches Bead over foil surface Improper sealing

Limitations Of Manual Inspection

Traditionally, manual inspection is common practice in the packaging and printing industry. However, this method of quality control has certain limitations as below:

Inaccurate Results

Human inspection accuracy is variable and subject to several factors, such as turnover, fatigue, and inconsistency. Undetected or inconsistent inspection may result in quality variations across different shifts.

Missed Defects

Manual inspection is limited to only defects that are listed in the SOPs. Unanticipated or defects beyond the manual are not identified by human inspectors, primarily because they lack the training and understanding.

No Records Available

In most cases, no records are maintained when quality checks are done with manual inspections. Traceability is difficult and management is unable to make accurate decisions that improve operational efficiencies, productivity, and profitability.

Fight these limitations

Kiara Sorting and Inspecting packaged drinks for absence and presence of expiry date on the tetrapack with the use of Machine Learning and artificial intelligence

How AI-based vision inspection systems benefit the packaging and printing industry

AI-based vision inspection systems can detect unnoticed defects within seconds, which makes them more accurate, consistent, quick, and detailed. Moreover, unlike human fatigue, machine vision systems tirelessly perform 100% accurate inspections improving quality. Here are several benefits of automated vision systems:

Greater accuracy when compared to human inspection resulting in zero errors
Cost efficiency as rework and product recall are eliminated
Lower wastage as defects are identified without delays reducing production costs and improving productivity
Consistently delivering high-quality products enhances customer satisfaction and improves brand reputation
Improved bottom line by utilizing personnel in other production areas thereby maximum efficient use of limited resources
By ensuring 100% defect-free products consistently, you can explore high-end and international markets

The printing and packaging industry faces several challenges and line cameras can significantly improve quality control requirements. Machine vision technology can open new opportunities and is capable of providing the best method to detect defects and are customisable based on the specific requirements of your production line.


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