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Automated vision inspection for bottle crates

Wireless production line accounting and defect registration system for dairy processing
June 19, 2026 by
Ričards Sleņģis

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A vision inspection system for production and packaging lines that checks the whole crate in a single image and confirms every required bottle is present and correctly capped.


20

bottles in the box

1

camera

0

incomplete crates reaching the customer

The problem

Incomplete crates go unnoticed until they're already at the customer

Crates missing one or more bottles appear on the line from time to time. Manual checking is slow and uneven, so some incomplete crates slip through — and the customer receives less than they paid for.

 Missing bottles

A crate should hold 20 bottles. When one is missing, it's often caught only at the customer's end, not on the line.

 Manual inspection is not reliable

Checking by eye is slow, tiring and dependent on attention. Defects get through.

 Uncapped bottles

Even when the count is right, individual bottles can be left without a cap — and it goes unnoticed.

 Claims and penalties

Incomplete orders mean claims, returns, and additional costs — and damaged trust.

How it works

Each crate is checked with a single image — automatically

The box arrives at the camera

The photoelectric sensor detects the arrival of the box and turns on the lighting.

The position is confirmed

Another sensor confirms that the box is directly under the camera and sends a signal for the image to be taken.

The camera checks the entire box

The Banner iVu Plus TG captures a high-quality image in the light box and counts the caps to determine whether all bottles are in place and capped.

Incomplete box is marked

If a bottle or cap is missing, the system outputs a rejection signal in real time with light and sound indication.

What the system consists of

System architecture

Bottle crate inspection conveyor A crate travels along a conveyor belt, stops under a vision camera with a red light box, then either passes or is rejected. cam iVu Plus TG camera red LED light box position sensors
Ready

System components

Banner iVu Plus TG Vision sensor — captures the crate and counts the caps View product → Banner WLF12 Pro Flexible LED strip — even red light inside the light box View product → Banner S18-2VPDS-Q8 Photoelectric sensor — detects crate position and triggers capture View product →

What it changes day to day

From assumptions to accurate data

The client receives a full box
Each box that leaves the line is checked — the client receives exactly the goods they paid for.

Defects are caught on the spot
An incomplete box is marked in real time with a light and sound signal — not later at the client.

Fewer complaints and costs
Fewer incomplete orders mean fewer returns, fines, and disputes — and a more stable reputation.

Consistent checking without fatigue
The system checks each box equally throughout the shift — without fluctuations in human attention.

Questions and answers

Frequently asked questions

Yes. The inspection algorithm is configured according to the box size and the number of bottles — in this case for 20 bottles, but it can be changed.

A closed light box with configured red LED lighting eliminates the influence of external light and creates uniform conditions so that the image is always of high quality and recognition is accurate.

Yes. The system counts the caps and marks the box if any bottle is without a cap or completely missing.
The system outputs a rejection signal in real time with light and sound indication so that the operator can respond immediately on the line.

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We will develop a customized visual inspection system for your line. Tell us about your packaging process.


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Wireless production-counting and defect-logging system for dairy processing
Wireless production line accounting and defect registration system for dairy processing