The challenge
Under-filled bottles create both a compliance exposure and a customer complaint problem, while over-filling gives away product on every unit. Checking by eye against a sight line is slow and inconsistent between operators and shifts.
How we approached it
Backlit inspection so the meniscus reads as a hard edge regardless of liquid colour or clarity
Fill height measured in millimetres against configurable upper and lower limits
Simultaneous cap presence and cap seating check in the same image
Reject gate downstream of the camera with confirmation sensing
The outcome
Consistent fill verification independent of operator or shift
Both under-fill and over-fill flagged, protecting compliance and giveaway
Cap faults caught in the same station rather than needing a second camera
See it running
Applications
Fill Level ControlLeak DetectionCap PresenceFast Throughput