Automated Vision Inspection for Bottle Crate Filling
In beverage production, precision is non-negotiable. Missed bottles in crate filling not only disrupt logistics but also damage brand trust. We delivered a fully integrated, camera-based quality control solution using Banner Engineering components to ensure every crate contains exactly 20 bottles before shipment — no exceptions.
📌 The Challenge
A leading brewery encountered recurring issues where robotic crate loaders failed to insert all 20 bottles. These underfilled crates often went unnoticed until they reached customers — resulting in complaints, returns, and inefficiencies. Manual inspection was too slow and unreliable. An automated, real-time solution was needed.
🔧 Complete Solution
We designed and installed a smart vision system that combines high-performance imaging, synchronized lighting, and trigger logic — all built for industrial robustness and precision. The system inspects an entire crate in a single image, detecting not only missing bottles but also bottles without caps.
Need a reliable way to verify crate completeness?
Tell us about your application — our team will help configure the best solution for your needs.
Vision Sensor: Banner iVu Plus TG
At the heart of the system is the iVu Plus TG image sensor — a powerful, self-contained vision sensor with integrated display and processing.
Captures a high-contrast image of the entire crate and runs an onboard inspection algorithm to count bottle caps. If fewer than 20 caps are detected — or if a bottle lacks a cap — it triggers a fail signal in real time.
Key specs:
- 752×480 pixel CMOS sensor
- Up to 60 fps image acquisition
- Built-in 6 mm lens and red LED ring light
- Ethernet, USB, and discrete I/O connectivity
- Integrated touch display or remote Vision Manager software control
- IP67-rated housing for industrial environments
Illumination: Red LED Strip – Banner WLF12 Pro
To ensure consistent and accurate cap detection, we used an industrial-grade LED light strip with focused red output.
Mounted inside a custom-built aluminum light hood, the WLF12 Pro generates high-contrast red illumination that enhances the visibility of cap edges. This ring-like reflection is key to accurate detection by the iVu vision sensor. The enclosed lighting environment also isolates the imaging area from external interference, maintaining consistent image quality.
Key specs:
- Programmable RGB LEDs — configured to emit red illumination for optimal contrast in vision tasks
- Fully sealed design (IP66/IP67/IP69K) — suitable for washdown and damp environments
- Cut-to-length flexibility — customized to match the crate’s inspection zone
- 120° beam angle — delivers wide, even light distribution across the full crate
Triggering Logic: Dual Photoelectric Sensors – Banner S18-2 Series
Two S18-2VPDS-Q8 photoelectric diffuse-mode sensors coordinate crate detection and camera activation.
Sensor 1: Detects crate entry → Activates the LED lighting
Sensor 2: Confirms crate alignment under the camera → Triggers image capture by the iVu sensor
This logic ensures accurate timing adjustments and minimal false triggers — maximizing reliability and minimizing system wear.
Key specs:
- Operating range: up to 300 mm
- Voltage: 10–30 V DC, PNP output
- Bright visible red LED for precise alignment
- IP67-rated cylindrical body (M18)
