Carton and pallet verification
Unit counts in open cases, case and pallet labels, orientation, and the data link to your PLC, MES or WMS.
Technical review: Frank GuoReviewed
A camera station at the end of the line can check that each case carries a readable label whose content matches the order or production data, that the case faces the right way, and, while the case is still open, that it holds the right number of units. It cannot count inside a sealed opaque case, and pallet label checks need labels in defined positions. Reading a barcode confirms its content; it does not grade its print quality.
What a carton and pallet station checks
Four checks, often split over several positions. Which you need is set at the sample test.
Units in an open case
Counts units or slots while the case is open and compares the result with the SKU count.
Case and pallet labels
Label present on the expected face, readable, and carrying the content expected for that case or pallet.
Case orientation
Case the right way round before the labeller or palletiser, judged from label, print or flaps.
Match against expected data
Read content compared with the order, batch or pallet ID held by the PLC, MES or WMS.
Where each check is feasible
| Situation | Camera check | Conditions |
|---|---|---|
| Open case, one visible layer | Usually feasible. | Check after the case packer, before the sealer. |
| Open case, several layers | Top layer only. | Check each layer as it goes in, or weigh the case. |
| Sealed, opaque case | Count not feasible. | Count before sealing or weigh. Labels and orientation can still be checked. |
| Case or pallet labels | Usually feasible. | Labels on known faces and zones; cases singulated, pallets at a defined stop. |
| Cases inside a built pallet | Not feasible from outside. | Only outer faces are visible; check cases before stacking. |
We check what your case packer, labeller and palletiser produce. We do not supply that equipment, robot palletising or AMR transport.
Where carton and pallet verification stops
We agree these boundaries before a project starts, so nobody expects the camera to do what it cannot.
Not covered by this station
- Counting inside sealed cases. Count before sealing, or weigh the case.
- Labels in random places. Labels anywhere on a wrapped pallet are not read reliably.
- Wrong data at source. If the WMS or MES expects the wrong ID, the label matches it and the error passes.
Works reliably when
- Cases arrive singulated. Gaps between cases and a known label face.
- Label positions are fixed. The labeller places every label on the same face and zone.
- Expected data arrives automatically. From the PLC, labeller, MES or WMS, not typed in at each order.
How the checks are laid out at the end of the line
Plan view of a typical arrangement. The real positions follow the site survey.
Swipe sideways to see the whole drawing →
What a pass and a reject look like
Illustrations, not images from a real line.
Label matches
The label is on the expected face, the barcode reads, and its content matches the order held by the WMS.
One unit missing
The case holds fewer units than the SKU count. Caught before the sealer closes the flaps.
Wrong label content
The label reads but carries an ID from another order, typical when a labeller queue gets out of step.
Where the expected data comes from, and what happens on a mismatch
The camera reads; the comparison needs data from your systems. Changes on the MES or WMS side are made by your IT team or supplier.
| System | Role in the check |
|---|---|
| Line PLC | Selects the SKU recipe; receives pass, fail and no-read; runs the reject or stops the line. |
| Labeller | Sends the data it has just printed, so printed and read content can be compared. |
| MES | Holds batch, order and expected count; stores the result per case. |
| WMS | Holds the expected pallet ID; releases the pallet for dispatch only after a match. |
On a mismatch or no-read, the case is diverted or the line stopped, or the pallet is held, and the image and reason are logged. Protocol support depends on the reader or controller model: HIKROBOT's catalogue lists protocols such as PROFINET, EtherNet/IP and Modbus on specific code reader models (vendor-stated). See PLC and reject integration.
How the station is accepted
False rejects and missed faults pull against each other. We define both, and how they are measured, before FAT and SAT.
False reject rate
The share of correct cases or pallets rejected, measured on agreed good samples at line speed.
Missed fault rate
The share of short cases, wrong labels and reversed cases that pass, measured with seeded faults.
Data link failure
A test of what happens when the PLC, MES or WMS link drops: the station must hold product, not pass it.
What to prepare for the sample test
We check your own cases and labels before proposing a station. We confirm quantities and shipping with you first.
Sample preparation guideGood samples
Packed cases and printed case and pallet labels from normal production.
Faulty samples
Short cases, wrong or damaged labels, labels on the wrong face, clearly marked.
Label specification
Label templates, barcode types and where each label goes on the case and pallet.
Data information
PLC, labeller, MES and WMS names, and example records of expected data.
Carton and pallet verification questions
Can a camera count the units inside a sealed case?
How are pallet labels checked against the WMS?
What happens when a label does not match or cannot be read?
Can the station check that both labels on a pallet carry the same ID?
Does reading the label prove it meets GS1 or retailer print-quality rules?
Where must the pallet labels be placed?
Sources
- GS1: Serial Shipping Container Code (SSCC) (standards body page, checked 2026-09-24)
- GS1 Logistic Label Guideline (standards body page, checked 2026-09-24; label placement and verification sections)
- HIKROBOT Machine Vision Smart Product Catalog, 2025 Q4 (PDF) (vendor catalogue, checked 2026-09-24; code reader protocol rows)
Request an assessment for this application
Tell us how cases and pallets are labelled and where the expected data is held, and send good and faulty samples. We will tell you what a station can check.