Machine Vision for Packaging Inspection
Reliable Inline Inspection of Packaging, Markings and Products
Packaging must protect products, contain all required components, be correctly sealed and carry unambiguous markings. Missing components, incorrect variants, defective print or unreadable codes can lead to production disruptions, rejects and customer complaints.
OCTUM develops and integrates custom machine vision and automated optical inspection systems for the quality inspection of primary and secondary packaging. Typical applications include tubes, labels, folding cartons, shipping cartons, trays, blister packs, bags and pouches, containers, product sets and other packaging formats.
The inspection systems check characteristics including presence, completeness, packaging condition, product variant, labels, print, variable text and 1D and 2D codes.
Each solution is engineered around the product, packaging material, relevant defect characteristics, target throughput and available installation space. Defective units can be detected directly within the production process, rejected automatically and, depending on the system configuration, documented in a traceable manner.
OCTUM USA provides regional coordination, technical support and service for customers across the United States, Central America and South America – backed by OCTUM’s machine vision and application expertise in Germany.
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Inspection Solutions for Packaging, Labels and Tubes
Our inspection solutions cover areas including:
OCTUM provides modular product solutions and custom-engineered machine vision systems for different packaging processes.
tube.inspect – Inspecting Tubes Before and After Filling
tube.inspect is a modular inspection system for metal, laminate and plastic tubes. Multiple inspection stations can be connected within a tube filling and sealing machine and operated centrally.
Typical inspection tasks include:
- Tube opening and geometry inspection
- Detection of visible particles and contamination
- Fold, seam and trim inspection
- Inspection of visible closure characteristics
- Print, OCR and OCV inspection
- Reading and verification of 1D and 2D codes
The modules are configured to suit the tube material, format, machine design, production speed and inspection objective.
label.inspect – Inspecting Labels and Markings
label.inspect checks labels and markings directly within the printing, labeling or packaging process.
Depending on the application, the system can inspect:
- Label presence and correct variant
- Position and alignment
- Visible label application defects
- Print and artwork
- Variable text using OCR and OCV
- 1D and 2D codes
- Consistency with recipe, work order or production data
Missing, incorrectly positioned or incorrectly printed labels can be detected at an early stage and the affected units can be rejected automatically.
pack.inspect – Inspecting Packaging Inline
pack.inspect checks products, packaging and packaging components directly within the packaging process.
Typical inspection tasks include:
- Presence and completeness
- Product and variant inspection
- Position and orientation
- Label and print inspection
- Text and code verification
- Inspection of closures, flaps and folds
- Detection of visible damage and foreign objects
One or more inspection stations can be integrated directly into the packaging machine and managed through a common operator interface.
![[Translate to English (USA):] [Translate to Englisch:] an einer automatisierten Verpackungslinie greift ein Pick&Place-Roboter verschiedene Produkte vom Band](/fileadmin/user_upload/content-bilder/Branchenl%C3%B6sungen/Verpackungstechnik/Weitere/pickandplace_375x248_-_%C3%9Cbersichtsseiten.jpg "Pick & Place Inspektion in der Verpackungstechnik – OCTUM")
Machine Vision for Pick-and-Place Applications
Pick-and-place robot gripping products using position data from a machine vision system
OCTUM machine vision systems can identify the type, position and orientation of products and transfer the calculated data to the machine or robot control system.
Products can therefore be picked up automatically, aligned and placed into packaging or transferred to subsequent process stations.
Possible functions include:
- Identification of different product types
- Detection of position and orientation
- Verification of product position
- Calculation of the gripping position
- Transfer of position data to the robot control system
- Inspection before or after the handling step
Pick-and-place solutions can be configured for bags and pouches, cartons, cups, jars, blister packs and many other products.
Is Your Application Not Listed?
Many packaging processes require a custom-configured inspection solution. OCTUM transfers proven machine vision concepts to new products, packaging formats and machine designs.
The decisive factors include the product and packaging, relevant defect characteristics, material and surface properties, product variants, target throughput, installation space, interfaces and documentation requirements.
You can write us using our contact form
OCR, OCV and Code Verification
Lot numbers, serial numbers, manufacturing dates, use-by dates and expiration dates can be read or verified against known reference values.
Barcodes, Data Matrix codes, GS1 codes, QR codes and other 1D and 2D codes can be decoded and compared with recipe, work order or production data.
Requirements for standards-based print quality verification or code grading must be defined and technically qualified for the specific project.
Packaging and Closure Inspection
Visible characteristics such as closed flaps, correct folds, closure positions, trim edges, packaging contours and visible damage can be checked immediately after the packaging or closing process.
Optical inspection evaluates visible characteristics. It does not replace physical leak testing, seal integrity testing or seal strength testing.
Suitable for Different Packaging Types and Industries
The inspection systems are adapted to the packaging format, material, surface properties, production process and quality requirements.
Typical Industries
OCTUM develops packaging inspection systems for industries including:
- Pharmaceuticals
- Medical devices
- Cosmetics and personal care
- Consumer goods
- Chemical products
- Technical products and components
- Other automated packaging applications
Technical feasibility is evaluated for the individual product, packaging and actual process conditions.
Integrated into Packaging Machines and Production Lines
Reliable packaging inspection results from the coordinated interaction of image acquisition, product transport, machine communication, reject handling and data processing.
OCTUM integrates machine vision and AOI systems into both new packaging machines and existing production lines.
Depending on the project, the following aspects are considered:
- Camera, lens and lighting concept
- Packaging material and surface properties
- Product handling and inspection position
- Target throughput and available inspection window
- Triggers, encoders and other process signals
- Connection to the PLC and machine control system
- Pass/fail decisions
- Reject handling and reject verification
- Recipe and format management
- Central operation of multiple inspection stations
- Interfaces to MES and higher-level systems
- Storage and transfer of inspection data
- Long-term maintainability and serviceability
The achievable inspection performance depends on factors including the number and complexity of the inspection characteristics, packaging format, product spacing, image resolution, number of cameras and available evaluation time.
>> Learn More About System Integration
>> Evaluate Technical Feasibility
Packaging Inspection for Regulated Production Environments
For packaging applications in pharmaceuticals, medical devices and other regulated industries, it may not be sufficient simply to identify defective units. User access, changes to inspection programs and relevant inspection results may also need to be managed in a traceable manner.
For packaging processes used in FDA-regulated pharmaceutical or medical device manufacturing, the applicable quality system and documentation requirements depend on the product, intended use and manufacturer’s quality processes.
If an inspection system creates or manages quality-relevant electronic records or electronic signatures, requirements under 21 CFR Part 11 may also apply.
Depending on the project, OCTUM systems can incorporate functions including:
- Individual user accounts
- Role-based access management
- Logged user actions
- Audit trail functions
- Controlled recipe and format management
- Version and change history
- Storage of inspection and event data
- Lot and work order assignment
- Data integrity and traceability
- Interfaces to higher-level systems
- Documentation supporting qualification and validation
The specific system configuration depends on the intended use, product, operational processes, quality management system and the user’s validation strategy.
An inspection system alone does not establish FDA or regulatory compliance. However, it can provide technical functions and documentation that support the manufacturer’s quality, qualification and validation processes.
4. Commissioning and Long-Term Support
OCTUM installs the system, supports commissioning and configures the required inspection programs and product formats.
Following system handover, OCTUM continues to provide support with optimization, training, new formats, additional inspection characteristics, maintenance and long-term stable operation.
OCTUM USA coordinates regional support and on-site service across the United States, Central America and South America, with additional engineering and application expertise available from OCTUM Germany when required.
Why Choose OCTUM for Automated Packaging Inspection?
OCTUM has been developing machine vision and AOI systems for demanding production environments since 1996. Customers across the Americas benefit from regional coordination through OCTUM USA and the technical expertise of OCTUM Germany.
- Experience in industrial machine vision since 1996
- More than 6,000 systems installed worldwide
- OCTUM USA location in Charlotte, North Carolina
- Regional coordination for the United States, Central America and South America
- Service technicians based in the United States
- Direct access to OCTUM’s application, software and engineering expertise in Germany
- Modular solutions for tube, label and packaging inspection
- Custom machine vision systems for individual packaging processes
- Proprietary software solutions such as OCVis, OCTUMISEr and CV-Inspect
- Experience with high machine speeds and changing product formats
- Integration into new machines and existing production lines
- Experience with regulated production environments
- Support from feasibility studies through commissioning, service and training
For operators, this means reproducible inline inspection, early defect detection, fewer manual inspections, reliable product and variant assignment and a reduced risk of rejects and customer complaints.
Which Inspection Tasks Can Be Automated?
Typical tasks include presence and completeness inspection, product and variant inspection, position and orientation inspection, label and print inspection, OCR, OCV, code verification, packaging and closure inspection and the detection of visible foreign objects.
Is 100% Inline Inspection Possible?
Depending on the product, packaging, inspection characteristics, production speed and machine design, the inspection system can be engineered to inspect every unit during production.
Technical feasibility and the detectability of the individual defect characteristics are assessed for each project.
Can Variable Text and Codes Be Inspected?
Yes. Lot numbers, serial numbers, manufacturing dates, use-by dates and expiration dates can be read using OCR or verified against known reference values using OCV.
1D and 2D codes can be decoded and checked for content, data structure and consistency with production data.
Can Existing Packaging Lines Be Retrofitted?
Yes. OCTUM integrates machine vision and AOI systems into both new packaging machines and existing production lines.
Available installation space, product handling, machine speed, control interfaces, operator interaction and reject handling are considered during system design.
Can OCTUM Systems Support Regulated Manufacturing?
Depending on the project, OCTUM systems can incorporate functions such as role-based user management, audit trails, controlled recipe and format management, data integrity, traceability and documented inspection results.
These functions can support the manufacturer’s quality and validation processes. The inspection system itself does not establish FDA or regulatory compliance.
When Is a Feasibility Study Recommended?
A feasibility study is particularly useful for new packaging formats, difficult-to-detect defects, reflective or transparent materials, small codes, a high number of variants, demanding production speeds or limited installation space.
It provides a reliable technical basis for decision-making before implementation.
Discuss Your Packaging Inspection Application
Would you like to inspect packaging, tubes, labels, print, text, codes or an entire packaging process automatically?
Tell us about your product, packaging format, relevant quality characteristics, typical defect types, product variants, target throughput and planned installation conditions.
Please also let us know about any requirements relating to machine connectivity, reject handling, documentation, traceability or format management.
Together, we will determine which machine vision solution is technically suitable and can be integrated reliably into your packaging machine or production line.
OCTUM USA coordinates the next steps for customers in the United States, Central America and South America, with additional engineering and application support available from OCTUM Germany.
OCTUM USA Inc.
14045 South Lakes Drive
Charlotte, NC 28273
USA
+1 (980) 431-9540
info@octum-usa.com