{"id":24517,"date":"2022-07-06T11:31:00","date_gmt":"2022-07-06T10:31:00","guid":{"rendered":"https:\/\/stage.dataductus.com\/?post_type=cases&#038;p=24517"},"modified":"2024-11-07T09:30:37","modified_gmt":"2024-11-07T08:30:37","slug":"autonomous-detection-of-faulty-bottles","status":"publish","type":"cases","link":"https:\/\/ductus.global\/sv\/cases\/autonomous-detection-of-faulty-bottles\/","title":{"rendered":"Autonomous detection of faulty bottles in high-paced production"},"content":{"rendered":"\n<section id=\"slider-banner-block_426c23a5061e0ebab3c3601b38d4a769\" class=\"slider-banner-block alignfull loading\" style=\"height: 700px\" data-type=\"carousel\" data-frequence=\"8000\" data-speed=\"1000\">\n    <div class=\"banner-static-content\">\n\t\t        <ul>\n\t\t\t        <\/ul>\n    <\/div>\n    <div class=\"banner-container slide-left\" style=\"width: 100%\">\n\n\t\t\n                <div id=\"sub_block_426c23a5061e0ebab3c3601b38d4a769_0\" class=\"inner  small-text-block text-block-align-left has-fixed-align \" data-item=\"0\" style=\"max-width: 100%; width: 100%\">\n                    <div id=\"image_block_426c23a5061e0ebab3c3601b38d4a769_0\" class=\"background-image\" role=\"img\"  aria-label=\"Autonomous detection of faulty bottles in high-paced production\"  style=\"background-image:url(https:\/\/ductus.global\/wp-content\/uploads\/2022\/07\/glass-bottles-belt.jpg); background-position: 50% 50%\">\n\t\t\t\t\t\t                    <\/div>\n                    <div id=\"background_color_block_426c23a5061e0ebab3c3601b38d4a769_0\" style=\"opacity: 0.65\" class=\"overlay-color has-background has-ductus-brightblue-background-color\"><\/div>\n                    <div id=\"content_block_426c23a5061e0ebab3c3601b38d4a769_0\" style=\" max-width: 700px; background-color:\" class=\"inner-content has-text-align-left\">\n\t\t\t\t\t\t\n\n\n                            <h1 class=\"hero-title has-text-color has-ductus-white-color\" >Autonomous detection of faulty bottles in high-paced production<\/h1>\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<p class=\"hero-text has-text-color has-ductus-white-color\">CASE STUDY<\/p>\t\t\t\t\t\t\n                                                                        <div class=\"background-block-mobile \" style=\"opacity: 1\"><\/div>\n                        <div class=\"background-block has-background\" style=\"opacity: 1\"><\/div>\n                    <\/div>\n                <\/div>\n\n\t\t\t    <\/div>\n<\/section>\n\n\n\n\n<div style=\"height:40px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<p class=\"intro-text has-preamble-font-size\"><span class=\"TextRun SCXW111570557\" xml:lang=\"EN-US\" lang=\"EN-US\"><span class=\"NormalTextRun SCXW111570557\">Operators at Inpac were struggling to simultaneously fill, quality check and pack bottles during production. The two production lines fill, cap, and label 125 bottles each per minute. With several thousand bottles passing down the line every hour at breakneck speed, small faults were going undetected. Ductus was contacted to develop an autonomous detection system to solve this.<\/span><\/span><\/p>\n\n\n\n<div style=\"height:40px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<div class=\"wp-block-group alignfull case-study-short has-d-mocha-light-background-color has-background\"><div class=\"wp-block-group__inner-container is-layout-flow wp-block-group-is-layout-flow\">\n<div style=\"height:30px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<h3 class=\"wp-block-heading\" id=\"h-in-brief\"><span style=\"color:#06415b\" class=\"tadv-color\">In brief<\/span><\/h3>\n\n\n\n<div class=\"wp-block-columns is-layout-flex wp-container-core-columns-is-layout-9d6595d7 wp-block-columns-is-layout-flex\">\n<div class=\"wp-block-column is-layout-flow wp-block-column-is-layout-flow\">\n<h5 class=\"wp-block-heading has-ductus-orange-color has-text-color\" id=\"h-challenge\">Challenge\u202f<\/h5>\n\n\n\n<p>Help Inpac ensure they only ship bottles that are filled to the right level with the caps screwed on properly and with correctly attached labels that have a clearly visible date stamp.<\/p>\n<\/div>\n\n\n\n<div class=\"wp-block-column is-layout-flow wp-block-column-is-layout-flow\">\n<h5 class=\"wp-block-heading has-ductus-turquoise-color has-text-color\" id=\"h-solution\">Solution<\/h5>\n\n\n\n<p>Cameras inspect a bottle in its entirety and lighting enhances the appearance of any present defects. Custom-software analyzes images and signals an ejector when a faulty bottle is detected.<\/p>\n<\/div>\n<\/div>\n\n\n\n<div class=\"wp-block-columns is-layout-flex wp-container-core-columns-is-layout-9d6595d7 wp-block-columns-is-layout-flex\">\n<div class=\"wp-block-column is-layout-flow wp-block-column-is-layout-flow\">\n<h5 class=\"wp-block-heading has-ductus-turquoise-color has-text-color\" id=\"h-how-we-did-it\">How we did it<\/h5>\n\n\n\n<p>Together with Inpac, we designed, developed and deployed a unique solution to fit the bottling lines. This included designing image analysis algorithms to detect and reject faults and training AI to recognize the different parameters.<\/p>\n<\/div>\n\n\n\n<div class=\"wp-block-column is-layout-flow wp-block-column-is-layout-flow\">\n<h5 class=\"wp-block-heading has-ductus-brightblue-color has-text-color\" id=\"h-benefits\">Benefits<\/h5>\n\n\n\n<p>Thanks to the autonomous detection system, Inpac has drastically improved the output quality of the production lines. A Human-Machine Interface, HMI, alerts operators when something is amiss in production, effectively reducing wastage and increasing efficiency.<\/p>\n<\/div>\n<\/div>\n\n\n\n<div class=\"wp-block-columns is-layout-flex wp-container-core-columns-is-layout-9d6595d7 wp-block-columns-is-layout-flex\">\n<div class=\"wp-block-column is-layout-flow wp-block-column-is-layout-flow\">\n<h5 class=\"wp-block-heading has-ductus-darkblue-color has-text-color\" id=\"h-about-the-client\">About the client<\/h5>\n\n\n\n<p><a href=\"http:\/\/www.inpac.se\/\">Inpac<\/a> provides packaging solutions for pharmaceutics, probiotics, dietary health, and nutritional supplements. In addition, they are also a manufacturer and supplier of health and nutritional supplements. The company is privately owned and headquartered in Lund, Sweden.<\/p>\n<\/div>\n\n\n\n<div class=\"wp-block-column is-layout-flow wp-block-column-is-layout-flow\"><\/div>\n<\/div>\n\n\n\n<div style=\"height:60px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n<\/div><\/div>\n\n\n\n<div style=\"height:40px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<h3 class=\"wp-block-heading\" id=\"h-identifying-a-need\">Identifying a need<\/h3>\n\n\n\n<p>Inpac fills and packages large quantities of bottles every day, which are then distributed worldwide. Each customer has their own quality requirements and expectations of the delivered product. What is considered a minor flaw by some, might be a deal breaker for others. Thus, high quality at delivery is critical to minimize complaints and maximize customer satisfaction. This begins with quality on the two production lines.<\/p>\n\n\n\n<p>Prior to the project, there wasn\u2019t a dedicated quality inspection process in place. Instead, operators did their best to inspect the bottles when packing them. With a production rate of 125 bottles a minute per line, this was very challenging. Defects were, unsurprisingly, being packed and delivered. Inpac identified this as a weak link in their quality assurance process and turned to Ductus for help to solve the issue.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\" id=\"h-finding-a-solution\">Finding a solution<\/h3>\n\n\n\n<p>One key factor in designing an effective autonomous detection solution was the close collaboration between Ductus and Inpac. Combining Inpac\u2019s process expertise and Ductus\u2019s machine vision expertise, streamlined the entire assignment. It all started with a site visit, to clarify the conditions and any constraints.<\/p>\n\n\n\n<p>As a first step, a requirement specification was composed and agreed upon. A well-formulated requirement specification is crucial as, in the case of Inpac, it describes the scope and the prerequisites of the system, and specifies the characteristics defining a faulty bottle. Based on this, we were able to propose a custom-made system, which we then designed to meet the unique requirements of the products and production lines.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\" id=\"h-implementing-the-autonomous-detection-solution\">Implementing the autonomous detection solution<\/h3>\n\n\n\n<p>The solution consists of carefully chosen hardware in conjunction with software and analysis tools developed by Data Ductus. Three cameras and two panel lights, placed at a specific geometry, ensure that all present errors are visible in the captured images. When a faulty bottle is detected, this is signaled to an ejector, which removes the bottle from the conveyor belt.<\/p>\n\n\n<div class=\"wp-block-image is-resized\">\n<figure class=\"aligncenter size-full\"><img decoding=\"async\" width=\"869\" height=\"639\" src=\"https:\/\/ductus.global\/wp-content\/uploads\/2022\/07\/inpac.png\" alt=\"The image shows three images of bottles where two are faulty and one is approved.\" class=\"wp-image-24985\" style=\"width:650px\" srcset=\"https:\/\/ductus.global\/wp-content\/uploads\/2022\/07\/inpac.png 869w, https:\/\/ductus.global\/wp-content\/uploads\/2022\/07\/inpac-300x221.png 300w, https:\/\/ductus.global\/wp-content\/uploads\/2022\/07\/inpac-768x565.png 768w, https:\/\/ductus.global\/wp-content\/uploads\/2022\/07\/inpac-68x50.png 68w, https:\/\/ductus.global\/wp-content\/uploads\/2022\/07\/inpac-600x441.png 600w\" sizes=\"(max-width: 869px) 100vw, 869px\" \/><figcaption class=\"wp-element-caption\">These are three examples of images. A red frame indicates a problem while a green frame means that the bottle is approved. The one on the left is faulty due to wrong filling level. The one in the middle is faulty due to a creased label.<\/figcaption><\/figure>\n<\/div>\n\n\n<p>The image analysis algorithms are designed to measure label position and filling level, and detect defects such as label creases and caps that are not properly screwed on. To adjust the sensitivity of the algorithm, so only faulty bottles are rejected, several parameters had to be tuned. If batches or baseline specifications change, AI methods can be used to find optimal parameter sets based on training data of correct and faulty bottles.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\" id=\"h-ensuring-stable-operation\">Ensuring stable operation<\/h3>\n\n\n\n<p>With an hour of downtime corresponding to 15,000 bottles, Ductus offers a wide range of cost-effective support agreements. Diagnostics and planned maintenance can be performed with remote access to the autonomous detection system. Most incidents can be resolved remotely by analyzing error logs and collected data. In some cases, on-site operators can get guidance to solve an issue. If hardware has been damaged, replacement may require on-site visits.<\/p>\n\n\n\n<div class=\"wp-block-group\"><div class=\"wp-block-group__inner-container is-layout-flow wp-block-group-is-layout-flow\">\n<h3 class=\"wp-block-heading\">Enjoying the benefits<\/h3>\n\n\n\n<p>Machine vision systems collect a lot of valuable information from production lines. We compile statistics from the bottling process and present them in an easily accessible graphical user interface. This allows Inpac to better understand their production line and identify bottlenecks or detect irregularities before they impact the quality of production.<\/p>\n<\/div><\/div>\n\n\n<div class=\"cta-button wp-block-button ductus-cta-block aligncenter\">\n\t<div class=\"wp-block-button\"><a href=\"https:\/\/ductus.global\/formpage?d=Zm9ybT0yJnRpdGxlPUF1dG9ub21vdXMgZGV0ZWN0aW9uIG9mIGZhdWx0eSBib3R0bGVzIGluIGhpZ2gtcGFjZWQgcHJvZHVjdGlvbiZidXR0b25fdGV4dD1Db250YWN0IHVzIHRvIGdldCBtb3JlIGluZm9ybWF0aW9uJmJ1dHRvbl9jbGFzcz1oYXMtZHVjdHVzLWdyZWVuLWJhY2tncm91bmQtY29sb3IgbWQmcmVzcG9uc2libGUmcmVkaXJlY3RfdXJsJnNlbmRfdXJsPWh0dHBzOi8vZHVjdHVzLmdsb2JhbC9zdi93cC1qc29uL3dwL3YyL2Nhc2VzLzI0NTE3LyZyZWdpb249QXV0b25vbW91cyBkZXRlY3Rpb24gb2YgZmF1bHR5IGJvdHRsZXMgaW4gaGlnaC1wYWNlZCBwcm9kdWN0aW9u\" role=\"button\" title=\"Contact us to get more information\" target=\"_blank\" class=\"ductus-btn-angle has-ductus-green-background-color md\"  data-gtmtrack=\"true\" data-trackelement=\"form-button\" data-trackvalue=\"Contact us to get more information\">Contact us to get more information<\/a><\/div><\/div>\n\n\n\t\t<section id=\"social-share-block_f8b3cf23a03ab6c06a8cf90823886af2\" class=\"ductus-gutenberg ductus-social-share-block\">\n\t\t\t<div class=\"inner\">\n\t\t\t\t<nav class=\"social-share post-24517\" role=\"navigation\" aria-label=\"Social Links Menu\"><div class=\"menu-social-container\"><ul class=\"social-links-menu\"><li class=\"menu-item\"><a class=\"social-share-link social-share-x\" title=\"x\" href=\"https:\/\/twitter.com\/intent\/tweet?text=Autonomous%20detection%20of%20faulty%20bottles%20in%20high-paced%20production&amp;url=https%3A%2F%2Fductus.global%2Fsv%2Fcases%2Fautonomous-detection-of-faulty-bottles%2F\" target=\"_blank\" rel=\"noopener\" alt=\"Share on X\"><svg class=\"svg-icon\" aria-hidden=\"true\" role=\"img\" focusable=\"false\" width=\"24\" height=\"24\" viewBox=\"0 0 24 24\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\"><path d=\"M13.982 10.622 20.54 3h-1.554l-5.693 6.618L8.745 3H3.5l6.876 10.007L3.5 21h1.554l6.012-6.989L15.868 21h5.245l-7.131-10.378Zm-2.128 2.474-.697-.997-5.543-7.93H8l4.474 6.4.697.996 5.815 8.318h-2.387l-4.745-6.787Z\"><\/path><\/svg><\/a><\/li><li class=\"menu-item\"><a class=\"social-share-link social-share-facebook\" title=\"facebook\" href=\"https:\/\/www.facebook.com\/sharer\/sharer.php?u=https%3A%2F%2Fductus.global%2Fsv%2Fcases%2Fautonomous-detection-of-faulty-bottles%2F\" target=\"_blank\" rel=\"noopener\" alt=\"Share on Facebook\"><svg class=\"svg-icon\" aria-hidden=\"true\" role=\"img\" focusable=\"false\" width=\"24\" height=\"24\" viewBox=\"0 0 24 24\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\"><path d=\"M12 2C6.5 2 2 6.5 2 12c0 5 3.7 9.1 8.4 9.9v-7H7.9V12h2.5V9.8c0-2.5 1.5-3.9 3.8-3.9 1.1 0 2.2.2 2.2.2v2.5h-1.3c-1.2 0-1.6.8-1.6 1.6V12h2.8l-.4 2.9h-2.3v7C18.3 21.1 22 17 22 12c0-5.5-4.5-10-10-10z\"><\/path><\/svg><\/a><\/li><li class=\"menu-item\"><a class=\"social-share-link social-share-linkedin\" title=\"linkedin\" href=\"https:\/\/www.linkedin.com\/shareArticle?mini=true&#038;url=https%3A%2F%2Fductus.global%2Fsv%2Fcases%2Fautonomous-detection-of-faulty-bottles%2F&amp;title=Autonomous%20detection%20of%20faulty%20bottles%20in%20high-paced%20production\" target=\"_blank\" rel=\"noopener\" alt=\"Share on Linkedin\"><svg class=\"svg-icon\" aria-hidden=\"true\" role=\"img\" focusable=\"false\" width=\"24\" height=\"24\" viewBox=\"0 0 24 24\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\"><path d=\"M19.7,3H4.3C3.582,3,3,3.582,3,4.3v15.4C3,20.418,3.582,21,4.3,21h15.4c0.718,0,1.3-0.582,1.3-1.3V4.3 C21,3.582,20.418,3,19.7,3z M8.339,18.338H5.667v-8.59h2.672V18.338z M7.004,8.574c-0.857,0-1.549-0.694-1.549-1.548 c0-0.855,0.691-1.548,1.549-1.548c0.854,0,1.547,0.694,1.547,1.548C8.551,7.881,7.858,8.574,7.004,8.574z M18.339,18.338h-2.669 v-4.177c0-0.996-0.017-2.278-1.387-2.278c-1.389,0-1.601,1.086-1.601,2.206v4.249h-2.667v-8.59h2.559v1.174h0.037 c0.356-0.675,1.227-1.387,2.526-1.387c2.703,0,3.203,1.779,3.203,4.092V18.338z\"><\/path><\/svg><\/a><\/li><li class=\"menu-item\"><a class=\"social-share-link social-share-mail\" title=\"mail\" href=\"mailto:?subject=Share: Autonomous%20detection%20of%20faulty%20bottles%20in%20high-paced%20production&amp;body=Autonomous%20detection%20of%20faulty%20bottles%20in%20high-paced%20production%0D%0A%0D%0A%0D%0A%0D%0ARead more: https%3A%2F%2Fductus.global%2Fsv%2Fcases%2Fautonomous-detection-of-faulty-bottles%2F\" target=\"_blank\" rel=\"noopener\" alt=\"Share on Mail\"><svg class=\"svg-icon\" aria-hidden=\"true\" role=\"img\" focusable=\"false\" width=\"24\" height=\"24\" viewBox=\"0 0 24 24\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\"><path d=\"M20,4H4C2.895,4,2,4.895,2,6v12c0,1.105,0.895,2,2,2h16c1.105,0,2-0.895,2-2V6C22,4.895,21.105,4,20,4z M20,8.236l-8,4.882 L4,8.236V6h16V8.236z\"><\/path><\/svg><\/a><\/li><\/ul><\/div><\/nav>\n\t\t\t<\/div>\n\t\t<\/section>\n\n\n\n<div style=\"height:150px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n","protected":false},"excerpt":{"rendered":"<p>Operators at Inpac were struggling to simultaneously fill, quality check and pack bottles during production. The two production lines fill, cap, and label 125 bottles each per minute. With several thousand bottles passing down the line every hour at breakneck speed, small faults were going undetected. Ductus was contacted to develop an autonomous detection system [&hellip;]<\/p>\n","protected":false},"author":5,"featured_media":24986,"parent":0,"comment_status":"closed","ping_status":"closed","template":"","meta":{"_acf_changed":false,"footnotes":""},"categories":[11,20],"tags":[4251],"class_list":["post-24517","cases","type-cases","status-publish","has-post-thumbnail","hentry","category-case_studies","category-case-studies-it-consulting","tag-ai-data-analysis"],"acf":[],"_links":{"self":[{"href":"https:\/\/ductus.global\/sv\/wp-json\/wp\/v2\/cases\/24517","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/ductus.global\/sv\/wp-json\/wp\/v2\/cases"}],"about":[{"href":"https:\/\/ductus.global\/sv\/wp-json\/wp\/v2\/types\/cases"}],"author":[{"embeddable":true,"href":"https:\/\/ductus.global\/sv\/wp-json\/wp\/v2\/users\/5"}],"replies":[{"embeddable":true,"href":"https:\/\/ductus.global\/sv\/wp-json\/wp\/v2\/comments?post=24517"}],"version-history":[{"count":2,"href":"https:\/\/ductus.global\/sv\/wp-json\/wp\/v2\/cases\/24517\/revisions"}],"predecessor-version":[{"id":32621,"href":"https:\/\/ductus.global\/sv\/wp-json\/wp\/v2\/cases\/24517\/revisions\/32621"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/ductus.global\/sv\/wp-json\/wp\/v2\/media\/24986"}],"wp:attachment":[{"href":"https:\/\/ductus.global\/sv\/wp-json\/wp\/v2\/media?parent=24517"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/ductus.global\/sv\/wp-json\/wp\/v2\/categories?post=24517"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/ductus.global\/sv\/wp-json\/wp\/v2\/tags?post=24517"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}