The challenge
Misprinted labels were reaching packing because operators could not reliably catch defects at line speed. Manual sampling meant faults were often discovered after a full batch had run, forcing rework of the entire lot rather than rejection of a handful of strips.
How we approached it
Line-scan camera synchronised to the web with an encoder, so inspection stays aligned regardless of speed changes
Reference-based comparison against an approved artwork master, tolerant of registration drift
Detection of missing text, smearing, colour deviation and registration error in one pass
Reject actuator triggered per strip, with a rolling event log for QA review
The outcome
Defective strips are removed inline instead of being found at packing
Rejection is per-strip rather than per-batch, cutting scrap significantly
A time-stamped image record exists for every rejection, supporting audit requirements
See it running
Applications
Misprint DetectionLabel RejectionInline Quality ControlAuto Sorting
Industries
PharmaceuticalPackaging & Logistics