High-Precision Aluminum Foil Seal Inspection System | Infrared Thermal Imaging + AI Vision | Detect Bottle Cap Defects
Ideal Applications:
Food & Beverage: Mineral water, canned goods, sauces, and carbonated drinks;
Pharmaceuticals: Oral liquids, medicine bottles, and healthcare products;
Cosmetics & Personal Care: Shampoos, lotions, and skincare bottles;
Sealing Defect Analysis & Detection Methods
| Defect Type | Thermal Signature | Detection Method |
| Missing Foil Cap | No thermal trace on bottle neck; temperature matches background. | Temperature threshold comparison. |
| Reverse Foil Cap | Foil faces wrong direction; uneven thermal distribution. | Orientation detection + gradient analysis. |
| Foil Edge Lifting | Edge temperature < center (air convection accelerates heat loss). | Edge temperature difference >2°C. |
| Crooked Cap | Asymmetrical thermal pattern due to misalignment. | Geometric matching + symmetry analysis. |
| Foil Edge Damage | Higher temperature at damaged point (reduced heat conduction). | Anomaly clustering analysis. |
| Double Foil Cap | Overlapping thermal layers create abnormal hot spots. | Multi-layer temperature modeling. |
| 1/4/1/8 Loose Cap | Localized low-temperature zones from poor sealing. | Regional temperature statistics. |
| Bottle Neck Contamination | Foreign objects block heat flow, creating hot/cold spots. | Shape recognition + temperature anomaly. |
Specification:
| No. | Parameter | Value / Specification |
| 1 | Max Inspection Speed | 220 bottles/min (varies depending on product size) |
| 2 | Pass Rate | ≥ 99.99% |
| 3 | Applicable Specifications | Cap Diameter: 9mm–150mm Bottle Height: 50mm–500mm |
| 4 | Matching Line Speed | ≤ 22 m/min |
| 5 | Inspection Categories | No cap, missing foil liner, skewed cap, high cap, reverse foil liner, double foil liner, damaged foil edge, warped foil edge, weak seal (underpower), weak seal (overpower), bottle neck contamination/trapped material, 1/4 loose cap, 1/8 loose cap |
| 6 | Air Consumption | 30 L/min |
| 7 | Power Supply | AC 220V ± 10%, 50/60Hz |
| 8 | Power Consumption | ≤ 1.5 kW |
| 9 | Operating Temperature | -10°C to 60°C |
| 10 | Equipment Dimensions | 490 mm × 750 mm × 1800 mm |
| 11 | Image Accuracy | ±0.05 mm |
| 12 | Camera Sensor | Imported detector (Polysilicon material) |
| 13 | Camera Frame Rate | 50 Hz full temperature stream |
| 14 | NETD | 50 mK @ 25°C |
Electrical Configuration List
| No. | Component Name | Brand / Description |
| 1 | PLC CPU | Siemens |
| 2 | Touch Screen (HMI) | Yiyao |
| 3 | Photoelectric Sensor | Sick |
| 4 | Switching Power Supply | Mean Well (MW) |
| 5 | Pneumatic Cylinder | AirTAC |
| 6 | Solenoid Valve | AirTAC |
| 7 | Push Button Switch | Schneider |
| 8 | Warning Light / Tower Light | 5i |
| 9 | Circuit Breaker | CHINT |
| 10 | Camera | Domestic Chip |
| 11 | Industrial PC (IPC) | Newvin |
Technical Advantages
Customized Infrared Camera
Higher resolution than similar devices (384*288 pixels), ensuring superior inspection accuracy.
Imaging distance ranges from approximately 20times focal length to infinity.
Manual focus mechanism.
Inspection Algorithm
From the thermal distribution images, the correlation with defects is not always obvious. In particular, many normal seals do not exhibit a perfectly uniform heat distribution, and differences are often only reflected in subtle details. Therefore, this imposes extremely high demands on the inspection algorithm.
Newvin adopts advanced deep learning technology. Trained on a large volume of field samples, the network model is capable of precisely detecting any subtle variations, guaranteeing the overall accuracy of inspection. Additionally, the strictness of the model can be adjusted by setting thresholds within the software.
| Feature / Advantage | Description |
| User-Friendly & One-Key Start | Operators can start inspection with a single click. The operation process is simple, intuitive, and highly user-friendly. |
| Reliable Operation ($ge 99.99%$ Pass Rate) | Comprehensive false rejection rate is 0.5%, with an overall inspection accuracy rate reaching 99.99%. |
| 30-Second Product Changeover | All production data can be saved. When switching to saved specifications, a single click confirms the settings, significantly reducing machine setup time. |
| One-Key Export of Production Data | Production data supports one-key export (including output, pass rate, and rejection count per unit time) for convenient manual traceability. |
Infrared Visual Inspection Equipment: Comprehensive Bottle Cap & Foil Seal Defect Detection installation
Frequently Asked Questions
Q: Can the system adapt to different bottle shapes and sizes?
A: Yes. Our system offers customizable parameter settings to accommodate round, square, and irregular bottle shapes, as well as various cap and foil seal dimensions.
Q: How does the system handle defective products?
A: The system triggers an automatic rejection mechanism immediately upon detecting a defect. It also generates detailed reports with defect type statistics, which can be exported for further analysis.
Q: Is installation and maintenance complex?
A: No. The system features a modular design for quick, hassle-free integration with existing production lines. Routine maintenance only requires periodic lens cleaning, and remote diagnostic support is available to minimize downtime.
