Print Inspection System to Overcome Manufacturing Defects
To check the Poly-Pouch and its manufacturing defects and to make bunches with unique barcode numbers.
The Targeted Industry
Printing and packaging industry.
Problem Statement
The material of Poly-pouch was highly reflective & the tracking of the pouch from the production line was tricky.
Objective Set by Customer
- Poly-pouch for packaging industry
- To check the Poly-Pouch for its manufacturing defects in high-speed pouch making machine
- To make bunches with unique barcode numbers
Challenges & Solutions
Type of Challenge 1 :
The material of Poly-pouch was highly reflective.
Type of Solution 1 :
We developed custom Tunnel Light with Dome Effect to objectify the reflection. To maximize the size of the pouch was 18 inch X 12 inch, however at that time there was no readily available lighting solution in the market.
Type of Challenge 2 :
The tracking of the pouch from the production line (as it was in roll form) to the Inspection station where a single pouch is formed was somewhat complex. Due to orientation of the pouch on the inspection conveyor, the serial number was not visible.
Type of Solution 2 :
We suggested printing QR code along with numbering so that the camera can MAP the number with QR and can record data accordingly.
Overall Set of Solutions by OptoPixel
- Customized Machine with High-Speed camera with the inspection speed of 150 parts/minute.
- The two cameras installed on customer existing machine lines for the number verification.
- Production Report generation on regular basis
- Automatic Bunching with GOOD Production as per the pre-defined Bunch-size.
- At the end of the Bunch, there will be a Parent Label generation from the label printer.
Implementation of OptoPixel’s Solutions
- Provided Fully Automatic Machine with High-Speed Camera and Rejection System
- Successfully operated in industrial environment
- Custom size bunch making as per the customer’s dispatch order.
- Decreased manpower and increased quality of the production
