Norsk
BosanskiHigh-Speed 3D Flap Inspection for Pastille Boxes
By deploying high-speed 3D laser scanners, we eliminated a critical packaging defect. The color-agnostic system inspects physical box geometry rather than artwork, automatically rejecting unglued front flaps at over 400 units per minute.
The Challenge
The client operates a high-speed confectionery packaging line where pastille boxes are glued and sealed. A persistent problem was a high rate of boxes with unglued front flaps reaching the final packing stage.
The root cause was visual complexity – varying colors, glossy finishes, and shifting artwork patterns made traditional 2D color cameras highly unreliable. Shadows and reflections caused excessive false rejects, or worse, allowed open boxes to pass undetected all the way to the end customer.
The Solution
We deployed an advanced 3D Laser Scanning and Profiling system that is entirely color-agnostic. Rather than analyzing print or color, the sensors generate a real-time point cloud – a precise topographical map of each box surface.
The system instantly determines whether the front flap is flush and properly sealed, or raised and unglued, by measuring physical height and geometry alone. This approach delivers flawless detection performance regardless of box color, artwork, or surface reflectivity.
Our Implementation Process
Audit & Testing
We tested multiple box designs in our lab to calibrate precise micron-level height thresholds for reliable detection of unglued and failed flaps.
Hardware Setup
Compact 3D profile sensors were mounted directly over the existing conveyor belt, requiring no heavy modifications or complex changes to the production line.
Lighting Setup
Laser profiling technology eliminates the need for external ambient lighting entirely, resulting in an incredibly compact and self-contained optical inspection setup.
PLC Rejection Link
The smart 3D vision system connects directly to a high-speed pneumatic ejector, automatically removing failed and open boxes from the line in real-time.
Proven Results
The Results & ROI
Zero Escapes
One hundred percent of open or unglued flaps are detected and removed automatically, ensuring no defective packaging ever reaches your end customer.
Self-Improving AI Models
Seamlessly transition between different product types and complex box artwork without any downtime or interruption to your high-speed automated production line.
Fast Format Onboarding
Achieve flawless inspection at over 400 boxes per minute, maintaining your full production throughput without any compromise to output volume or speed.
Dedicated Optimization
The system delivered a rapid return on investment by eliminating costly manual quality checks and preventing expensive customer complaints.
Trusted By Experts
What Our Industrial Partners Say
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