Norsk
BosanskiAnalyzing High Speed Direction Of Bottles
Future Then deployed an advanced all-in-one vision system for Orkla Home and Personal Care. It reliably decodes the orientation of transparent, reflective, and colored bottles at over 600 units per minute.
The Challenge
Inside a high-speed unscrambler machine, hundreds of chemical bottles tumble and spin in a chaotic stream every minute. Traditional optical sensors struggle against the visual complexity created by shifting colors, intense factory reflections, and varying liquid transparency levels.
This optical interference makes accurate bottle orientation detection nearly impossible, leading to frequent conveyor jams, crushed plastic containers, and costly production stoppages that continuously erode daily factory output and profit margins.
The Solution
We deployed a compact, all-in-one intelligent camera with an embedded processor, positioned directly above the circular conveyor. The system decodes the precise orientation of over 600 bottles per minute, effortlessly handling ultra-transparent plastics and highly reflective surfaces alike.
Orientation data is transmitted instantly to the unscrambler mechanism, allowing every bottle to be smoothly and accurately aligned without any human intervention – maintaining flawless high-speed mechanical synchronicity throughout the entire production shift.
Our Implementation Process
Audit & Testing
We thoroughly analyzed complex bottle geometries to identify optimal camera angles for reliable high-speed orientation decoding of transparent plastics.
Hardware Setup
A compact all-in-one smart camera with an embedded processor was installed directly above the circular conveyor, requiring no mechanical modifications.
Software Calibration
The integrated vision software was fine-tuned to track fast-moving bottles reliably while filtering out metallic glare, liquid reflections, and shifting surface colors.
Unscrambler IO Link
Using native industrial communication protocols, the system was connected directly to the sorting mechanism to deliver precise orientation commands.
Proven Results
The Results & ROI
Zero Jam Downtime
Conveyor jams and crushed plastic containers inside the unscrambler were completely eliminated, saving thousands of euros in mechanical repairs and labor costs.
Extreme Line Speed
The system delivers flawless bottle orientation at over 600 units per minute with zero impact on automated conveyor throughput or overall production velocity.
Chromatic Independence
Seamless handling of transparent, colored, and highly reflective bottles with no manual recalibration, production interruptions, or changeover downtime.
Rapid System Payback
The automated orientation system recovered its full investment within months by eliminating manual sorting shifts and significantly reducing plastic material waste.
Trusted By Experts
What Our Industrial Partners Say
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