Machine vision inspection applications
Industrial camera inspection for South African packaging, moulding and parts production lines, organised by the fault you need to catch.
Machine vision inspection applications are grouped here by the fault a camera station catches on the line. Choose the application from the fault you need to catch, not from the camera. Wrong or crooked labels point to label inspection; unreadable dates to OCR/OCV; low fill or missing caps to fill, cap and seal; scratches or flash to surface defects; out-of-size parts to measurement; missing items to presence and counting. A camera only sees what is visible, so every choice is confirmed on your own samples first.
Which application fits your problem?
Find your fault. The last column is the first question we ask.
| Your problem | Application | Check first |
|---|---|---|
| Missing, crooked or wrong labels | Label & print inspection | Is the label visible from one fixed position? |
| Date or batch code missing, smudged or wrong | OCR/OCV & date codes | Is the code printed in a consistent area? |
| Low fill, missing or tilted caps, no tamper band | Fill level, cap & seal | Can the fill line be seen through the container? |
| Scratches, dents, flash, short shots, contamination | Surface defect detection | Does lighting separate the defect from normal texture? |
| Lengths, diameters or hole positions out of limit | Dimensional measurement | Does the tolerance suit the field of view and optics? |
| Missing components, inserts or pack items | Presence, absence & counting | Is every item visible, not hidden under another? |
| Chipped finishes, cracks or foreign objects in empty containers | Empty containers & preforms | Is the container empty and clean enough to see through? |
| Holes, streaks or coating faults on a moving web | Web & line-scan inspection | Is there an encoder or a steady line speed to trigger on? |
| Wrong or missing case and pallet labels | Carton & pallet verification | Does the label sit on a known face of the case or pallet? |
| Part codes marked on metal or plastic not read | DPM code reading | How is the code marked, and on what surface? |
Describe the fault, not the solution: common searches and the page that answers them
Most people search for the problem they see on the line. These are typical phrasings we collected and where each is answered.
| What the line reports | Application | What a station does |
|---|---|---|
| “Wrong label on the bottle”, “label mix-up at changeover” | Label & print inspection | Label barcode or artwork checked against the SKU running |
| “Date code rubbing off”, “smudged or missing expiry date” | OCR/OCV & date codes | OCR/OCV of the date and batch code on every pack |
| “The printer ran out of ink”, “one digit got switched” | OCR/OCV & date codes | OCV against the expected string from the coder or PLC |
| “Sensor to detect bottle caps”, “crooked caps” | Fill level, cap & seal | A photo eye sees presence; a camera also sees tilt, height and the band |
| “Underfilled bottles”, “short fill” | Fill level, cap & seal | Fill line against a backlight on clear or translucent containers |
| “Glass fragments or dirt in returnable bottles” | Empty containers & preforms | Base, sidewall and finish cameras before the filler |
| “Camera to detect scratches and dents” | Surface defect detection | Lighting chosen to make the defect stand out |
| “Measure parts on the line without contact” | Dimensional measurement | Edges in the image, or a 3D laser profiler for heights |
| “Count products on a conveyor when they touch” | Presence, absence & counting | Outlines counted from above instead of gaps |
| “Leaflet or part missing from the kit” | Presence, absence & counting | Each location checked for its item |
| “Mixed cartons”, “barcode would not scan at the DC” | Carton & pallet verification | Open-case check and every case and pallet label read |
| “Printing errors during the print run” | Web & line-scan inspection | The printed web compared with the approved master |
| “Read laser-marked codes on metal parts” | DPM code reading | Fixed DPM reader with lighting set for the mark |
Where each check sits on a line
Each check sits straight after the step that can cause the fault, before the fault is hidden or packed. Your line may differ; the principle holds.
Swipe sideways to see the whole drawing →
Ten inspection applications
Each page explains what can be checked, where the limits are and what a sample test needs.
Label & print inspection
Catch missing, crooked, doubled or wrong-SKU labels, and incomplete print, before the product is packed.
OCR/OCV & date codes
Check that best-before dates, batch and lot codes are present, readable and correct, whether printed by inkjet, thermal transfer or laser.
Fill level, cap & seal
Find under-filled containers, missing or crooked caps and missing tamper bands. Visible seal checks only: this is not a leak test.
Surface defect detection
Find scratches, dents, flash, short shots, marks and contamination, where lighting can make them visible.
Dimensional measurement
Measure lengths, diameters, hole positions and gaps without contact. Achievable accuracy depends on field of view, optics and how the part is presented.
Presence, absence & counting
Confirm that every component, insert or item is present, and count units in a pack, tray or kit.
Empty containers & preforms
Inspect the base, sidewall and finish of empty bottles and jars, and the gate and body of PET preforms, before filling or blowing.
Web & line-scan inspection
Inspect continuous material with a line-scan camera, an encoder and a line light, and mark or map defects instead of rejecting parts.
Carton & pallet verification
Check case and pallet labels against the expected data, orientation and visible counts before goods leave the line.
DPM code reading
Read dot-peen and laser-marked Data Matrix codes on parts for traceability, and hand the result to the PLC or MES.
Complete stations for common South African lines
The applications above are organised by fault. Line solutions start from the line instead: each is a complete station with HIKROBOT hardware, installation and an indicative rand budget for a typical application. All line solutions by industry →
Returnable cratesMultipacksCan ends and dentsJuice box strawsDairy cupsBread bag closuresMeat tray labelsWine labelsSachets and pouchesStaple food bagsFruit export cartonsPlastic closuresFolder gluersPaint tinsCement bagsPipe and cable printRebar bundlesAssembly error-proofingTyre codesFasteners and turned partsGlue and sealant beadsDC scan tunnelPallet labels at dispatchCopper and carbon anodesEgg cartons and traysBottled water (PET)Aluminium extrusionsMachined part dimensional inspectionMachined hole and feature inspectionMachined part burr inspectionMachined part mix-up inspectionFood tray seal inspectionFood packaging version verificationBakery product vision inspectionReturnable glass bottle inspection
When a camera is the wrong tool
A camera sees the surface it is pointed at. Some quality questions need a different instrument, often alongside vision on the same line.
Needs another method
- Internal defects. Voids, cracks and foreign bodies inside a product or behind opaque material are not visible. X-ray inspection and metal detection are the usual tools.
- Leak tightness. A camera sees that a cap or seal is present and in position, not that the pack holds pressure. That needs a leak tester.
- Adhesive strength. Label position can be checked; how well it is bonded needs a mechanical test.
- Weight. A visible fill level is not a weight. Where net content must be proven, use a checkweigher.
Where vision fits
- Visible features. Presence, position, print, codes, shape and surface marks.
- Consistent presentation. A known position, or enough camera views.
- Defined faults. Agreed defects with good and bad samples.
When a vision sensor or a barcode scanner is enough
Not every check needs a full vision inspection system. This is where a simpler device answers the question.
| Device | Answers | Limit |
|---|---|---|
| Photoelectric sensor (photo eye) | Something is present at one point; counting spaced products; triggering a camera. | Cannot tell a right item from a wrong one. |
| Vision sensor | One or a few simple checks from one view: presence, orientation, a pattern, a count. | Few tools and views; many variants need a camera system. |
| Fixed barcode scanner (code reader) | Reading a barcode or 2D code and checking its content. | Reads codes only; it does not see labels, print or defects, and it does not grade print quality. |
| Machine vision inspection system | Several checks and views, recipes per SKU, images and results logged, reject tracked to the right product. | More engineering; justified when simpler tools cannot answer the question. |
Applications by industry
A typical example of each check per industry. A dash means uncommon there, not impossible.
| Application | Food & beverage | Plastics & packaging | Metal components | Agro-processing | Building materials |
|---|---|---|---|---|---|
| Label & print inspection | Labels after a changeover | Printed sleeves and decorated packs | — | Bag and pouch labels | — |
| OCR/OCV & date codes | Best-before dates and batch codes | — | Printed part and lot numbers | Dates and batch codes on bags | — |
| Fill level, cap & seal | Fill level, caps and tamper bands | — | — | Visible bag seal (not a leak test) | — |
| Surface defect detection | — | Short shots, flash and contamination | Scratches and dents on finished faces | Visible surface foreign matter | Cracks, chips and glaze faults on tiles |
| Dimensional measurement | — | Moulded part size and holes | Diameters, hole positions and gaps | — | Tile, block and board size |
| Presence, absence & counting | Units in a case or multipack | Liners and inserts in closures | Fasteners and clips in assemblies | Bags in a layer or bundle | — |
| Empty containers & preforms | Empty glass bottles before filling | PET preforms before blowing | — | — | — |
| Web & line-scan inspection | — | Film and printed web | Strip and sheet surface | — | Roofing sheet and board surface |
| Carton & pallet verification | Case and pallet labels | — | — | Pallet labels on bagged goods | — |
| DPM code reading | — | Moulded-in codes on parts | Dot-peen and laser Data Matrix | — | — |
What you can check about us
Statements you can verify on this site, not claims about results.
Johannesburg-based integrator
Stations designed, built and commissioned from Douglasdale Village, Johannesburg, for lines across South Africa.
Sample test before a quotation
Your good and faulty samples are imaged first; the quotation follows what the test shows.
Accepted against agreed figures
False rejects and escapes are agreed in writing and measured at FAT and SAT.
Limits stated on every page
Each application and line solution says what a camera will not do.
One tool chain
Stations are built on HIKROBOT cameras, code readers and VisionMaster software.
Named author, sources and dates
Technical pages name their author, list their sources and show the date of the last content update.
Inspection application questions
What industries use machine vision systems?
Which inspection should a plant start with?
Can one camera station do several checks?
Plan the complete inspection station
Choosing a check is the first step. Our machine vision inspection systems in South Africa overview brings together applications, a delivered project, indicative budgets and the path from sample testing to commissioning.
Describe the fault, not the solution
Tell us what is going wrong and send a few good and bad samples. We will say which checks apply and whether the defect is visible, before any proposal.