Consumer goods industry
Consumer goods automation.
Fast-moving consumer goods mean high speeds, many variants and zero tolerance for faulty packs. We supply vision inspection, robotic kitting with 3D vision and fault data collection that shows why the line has stopped.
A fast line, precise packing.
Consumer goods automation deals with packing and kitting at speeds at which a person cannot catch a defect. A shopper complains about a pack with a missing item or a box with a part missing. For the manufacturer that means complaints from retail chains and a loss of brand trust. At several packs per second there is no point relying on spot checks; every single unit has to be inspected.
Our engineering team has delivered, for example, piece count inspection in consumer packs of hygiene products. A line laser highlights the edges, a camera evaluates several images of each pack and an air nozzle blows faulty packs off the conveyor. The system runs at 2.5 packs per second and lets no faulty pack through. Operators can change product parameters or add a new type themselves in the operator software, without a programmer. We have also built a fully automatic robotic cell with 3D vision that unloads furniture parts from pallets and kits them for a packing line at an average cycle time of seven seconds.
On existing lines we unify fault messages from control systems made by different manufacturers, such as Siemens and Allen-Bradley, and send them to the higher-level system. You will see which fault costs the most time, and from the data we determine where further automation makes the most sense. We work for manufacturers in Slovakia and the Czech Republic.
Typical solutions for consumer goods.
Piece count inspection in packs
A laser and camera count the items in every pack and evaluate several images statistically. Incorrect packs are rejected automatically.
Vision with neural networks
For defects that are hard to describe, such as creased or deformed items, image evaluation by a trained neural network helps.
Packaging automation for consumer goods
A robot with 3D vision picks parts from pallets, adds components and places the finished kit on the conveyor. It changes its gripper automatically.
Fault and downtime data collection
Fault messages from the PLCs of both the production and packing sections of the line in one place and in the higher-level system for statistics and OEE.
Weighing and labelling of finished goods
Connection of scales, a unique number for every pack, barcode printing and data transfer to MES or an SQL database.
Buffer and conveyor control
Accumulation buffers and conveyor control keep the line running even during a brief failure of a downstream machine.
What we deliver to consumer goods manufacturers.
Inspection, robotics and data, connected to the lines you already have.
- Sample testing and feasibility verification for vision inspection
- Mechanical and electrical design, camera and lighting mounts
- Programming of vision systems and evaluation software
- Robotic cells with 3D vision and automatic gripper change
- Communication links between PLCs from different manufacturers
- Fault message collection, statistics and connection to MES
- Operator software in which the operator adds a new product without a programmer
- Training, 24/7 service and spare parts
Technologies in our consumer goods projects
How the cooperation works.
Consultation
We come to you, look at the operation or the brief and tell you what makes sense. Without obligation.
Concept and quote
Technical design, scope, schedule and price. Always with a reserve for what practice reveals.
Implementation
Engineering, manufacturing, installation, programming and commissioning. One team, one responsibility.
Operation
Operator training, documentation and a service contract according to how critical the technology is for your production.
Related services.
Machine vision
2D and 3D vision inspection for quality control, OCR and DMC code reading, error-proofing and traceability.
3D bin picking
A robot picks randomly placed parts from bins and pallets using 3D vision. Free test visit.
Production data collection
Historisation of data from PLCs and meters, high-availability historian, visualisation, reporting and remote monitoring.
Frequently asked questions.
Did not find your answer? Write to us and we will reply within 24 hours.
What does consumer goods automation involve?
Most often inspection of packs and piece counts, kitting and packing, palletising, weighing and labelling, and collection of line fault data. Even a single operation on an existing line can be automated.
Can a camera keep up with inspection at high line speeds?
Yes, if the camera, lighting and evaluation method are chosen correctly. For piece count inspection in packs we achieved 2.5 packs per second with a false reject rate below 0.1 per cent. We always verify feasibility on your samples.
What is 3D vision for a robot and when do I need it?
A 3D camera or scanner creates a point cloud of the working area, and software finds the position and orientation of the part within it. You need it when parts are not precisely positioned, for example on a pallet or in a bin.
Can operators add a new product to the inspection themselves?
Yes, if it is designed that way from the start. We supply operator software in which the operator changes product parameters or trains a new type without a programmer's help.
How much does vision inspection of packaging cost?
It depends on the number of features inspected, line speed, lighting, mechanical modifications and the reject method. Inspection on an existing conveyor is a much smaller investment than a robotic cell with 3D vision. We give a fixed price after testing samples and a technical concept.
Can you link machines from different manufacturers?
Yes. We create a communication link, for example between Siemens and Allen-Bradley, unify the fault messages and send them to the higher-level information system via TCP/IP.
Send us a sample pack.
Describe the product, the line speed and the defect you want to catch. We will get back to you within 24 hours to arrange a test on your samples and a free consultation.