Inspector

Inspector

An inspector is a quality control machine that verifies the interior and exterior of containers destined for liquid food products, ensuring product quality and integrity before reaching consumers. Inspectors also verify that liquids contained in filled bottles are free from defects and contamination.

Inspection systems use automatic ejection controlled by dedicated PLC to remove non-conforming containers from the production line. Various inspector types control different aspects: suspended particles in liquids, bottle bottom, sidewalls, cap presence, label presence, ring, and neck condition.

Empty Bottle Inspectors

Empty bottle inspectors are linear modular machines verifying quality, integrity, and cleanliness of containers before filling. Typically installed after the bottle washer and before the filler, these systems ensure absence of foreign bodies and liquid residues.

Electronic inspectors perform multiple control functions:

Background Inspection

Detection of opaque defects (foreign objects, organic contamination, glass infusions) and semi-transparent defects (cellophane fragments, etc.). Optional features include:

• Automatic blowing system for bottom cleaning
• Illumination lamp for enhanced visibility

Ring Inspection

Control of the bottle mouth to identify breaks, abrasions, chips, and seal surface defects. Special lighting highlights internal and external edges, detecting even minimal damage.

Optional compressed air blowing system removes water drops from ring and fillet, improving control performance and reducing false rejects. The system activates only during bottle passage to minimize air consumption.

Wall and Abrasion Inspection

Sidewall inspection detects opaque or semi-transparent foreign bodies, internal and external contamination, breaks, glass production defects, and abrasion degree (scuffing).

Control uses two separate modules:

• Input module — verifies bottle shape
• Output module — complete wall control via bottle rotation using independently motorized straps

A dedicated abrasion detection module evaluates wear degree against configurable thresholds, ejecting containers exceeding acceptable limits.

Threading Inspection

Thread control identifies breaks or abrasions using optical units displaying the thread as a light spiral on black background. The amplified image is processed by analysis software for effective defect detection.

Liquid Residue Detection

Container Dimension Control

Outline inspection rejects non-conforming containers:

• Height defects — too high or too low
• Neck damage — broken necks
• Diameter variations — too large or too small
• Orientation errors — overturned bottles on conveyor
• Glass shards — expelled before inspection to protect machine

Fill Level Inspectors

Fill level control verifies liquid level inside glass or plastic containers, including completely opaque containers, using high-frequency capacitive systems with high precision.

Main features:

• Self-learning of reference level
• Minimum and maximum threshold settings
• Display of counts and statistical data
• Transmission to external systems

Additional safety functions:

• Adjacent container burst detection — ejects potentially contaminated neighbors
• Programmable risk zone ejection — removes containers from filler revolutions where breakage occurred
• Wash signal activation — triggers cleaning at burst location

Cap Inspectors

Cap control systems verify presence of caps and/or wire cages using one or more sensors. Operating modes:

• Autonomous control — independent inspection station
• Level control extension — simultaneous or separate-point inspection

Output options include ejection system activation, line diversion, or luminous/acoustic alarms.

Advanced camera systems verify:

• Cap presence and completeness
• Warranty ring position and integrity
• Cap position and inclination against acceptance parameters
• Ring detachment or folding detection
• Codes on caps or capsules

Capsule Inspectors

Capsule control determines if heat-shrink capsules have been properly applied using one or more sensors. Can operate as autonomous control or level control extension, driving ejection systems or functioning as alarm indicators.

Label Inspectors

Label inspection systems verify presence of labels, ribs, and stamps (paper, plastic, self-adhesive, or glue-applied) via optical sensors positioned on the labeling machine.

Analysis levels:

• Presence and orientation of labels
• Relative position of multiple labels
• Graphic content, inclination, and integrity
• Detail verification — text, codes, capacities, alcohol content
• Collar and capsule inspection
• Label alignment to glass frieze reference
• Batch code presence verification

For wraparound labels or shaped bottles with outward-facing labels, line sensors control the conveyor directly.

Leak Testing Inspectors

Leak testing systems control plastic bottle integrity by compression testing, detecting micro-leaks and closing defects that could compromise product safety.

X-Ray Inspectors

X-ray inspectors using pulsed X-ray technology examine entire container contents after filling, detecting foreign particles:

• Glass splinters
• Hard plastic fragments
• Metal shavings

Suitable for both liquid and pasty products, X-ray technology is safe and non-impactful on food and beverage quality.

Empty Crate Inspectors

Crate inspection verifies:

• Crate height — detecting deformed or incorrect crates
• Foreign bodies between bottles (top view)
• Bottle height inside crate via ultrasonic detection

Defective crates eject to a transport belt beside the main conveyor.

Weight Control Inspectors

Final weight control verifies boxes, cartons, bundles, and drums, identifying non-compliant packages with missing items or non-conforming contents. This constitutes the ideal final check before palletizing.

Features:

• Fully automatic operation
• Self-learning calibration at format change
• Stored format recall
• Statistical data printing with date and time
• Ethernet interface for network connection

Ejection Systems

Effective inspection requires reliable ejection of defective containers. Two main ejector types exist:

Push Ejectors

Pneumatic cylinder ejectors push faulty containers to accumulation tables or reject bins. Adjustable height (center of gravity alignment) and depth (proximity to passing containers). Dynamic waste signal management based on instantaneous conveyor speed ensures compatibility with any inspection system.

Progressive Diverters

Progressive diversion systems solve lateral displacement challenges while maintaining container stability regardless of shape, fill level, or production speed. Multiple deviation segments create a dynamic guide during container passage, gently accompanying it to an alternate conveyor.

Suitable for all container types:

• Materials — glass, plastic, metal
• Shapes — cylindrical, conical, rectangular, triangular, oval

Microprocessor-controlled pneumatic cylinders activate each element based on encoder-analyzed conveyor speed.

Product Tracking Systems

Tracking systems maintain exact product position throughout inspection, ensuring no containers are missed. Features include:

• Integrated waste controls — verify defective products actually leave production flow
• Automatic test programs — periodic detection performance verification
• Continuous monitoring via Ethernet network
• Long-term result storage

Inspection Verification

Electronic inspectors can be programmed for periodic self-testing using sample containers prepared with specific defects. If testing succeeds, production continues; if not, the machine stops until verification confirms correct inspection capability.

Software enables image storage for easy access and further processing.

Purchasing Used Inspectors

Used inspection equipment offers savings of 35% to 60% compared to new machines. Key evaluation factors:

• Working hours — indicator of remaining service life
• Maintenance history — regular service by specialized technicians
• Overhaul status — mechanical and optical system condition
• Inspection requirements — matching capabilities to production needs
• Speed compatibility — ejection capacity matching line throughput
• Container types — glass, PET, can compatibility