OPTOMECH ENGINEERS PVT LTD

BOTTLE INSPECTION SYSTEM

BIS XL

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DEFECT DETECTION
 Bottle Inspection System

BIS XL Machine

BIS XL Machine checks for the following

visual defects in plastic blow molded bottles.

Container Base
Top sealing Surface
Outer Sidewall of Container
Neck / thread
Inside the Container

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 Bottle Inspection System

Container Base

Contamination
Thin wall
Holes
Incomplete Blowing
 Bottle Inspection System

Container base

Spots Contamination Thin Wall

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 Bottle Inspection System

Top Sealing Surface

Flashes and extra material

Under / Short Molding
Ovality
Diameters Variation
 Bottle Inspection System

Top sealing surface

Ovality Diameter Variation Under / Short molding

 Bottle Inspection System

Outer Sidewall of Container

Material inclusions

Holes and thin wall

Incomplete Blowing/shape variation

Color shade variations & color smears

Black Spots and burn spots

 Bottle Inspection System

Outer Sidewall

Material
Thin Wall Spots
inclusions 9
 Bottle Inspection System

Sidewall Defects

Extra Material Hole Short Molding

 Bottle Inspection System

Unstable bottom Parting line defect Shape Variation

 Bottle Inspection System

Neck / thread
Ratchet / Thread Damage
Geometric Characteristics
Contamination
Black Spots Burn spots
Holes and thin wall
Incomplete Blowing
Material Defects
 Bottle Inspection System

Thread Area

Black spots on thread area Thread damage Short molding

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 Bottle Inspection System

Inside the Container

Dark Spots

Material insert

Contamination
 Bottle Inspection System

Black Spots Contamination

 Bottle Inspection System

Clamp Conveyor for container

Inside inspection
base inspection
 Bottle Inspection System

Sidewall inspection
 Bottle Inspection System

Thread Inspection
 Bottle Inspection System

Sealing surface inspection

HARDWARE FEATURE'S
 Bottle Inspection System

Bottle inspection is a High Performance system for checking the

visual defects in plastic blow molded bottles.
The system consists of a conveyor, cameras with optics and
illumination, enclosure, data processor, and mechanism for
ejection of the rejected product.
The Whole system is mounted in a ergonomically &
aesthetically designed enclosure, with shielding provided for
external light.
11 high resolution cameras provide all round inspection.
Easily adjustable mechanical setup for changeover.

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 Bottle Inspection System

Remote controlled lift is provided, the height of the complete

upper body of the machine including the conveyors, can be adjusted,
this function enables the height to be adjusted as per customers
conveyor.

Smart USP, for all the control systems.

A large 21” touch screen monitor, provides user friendly interface

without the need for mouse and keyboard.

Castor wheels are provided, to easily move the machine from one
injection molding machine to another.

Door interlocks are provided with sensors.

Air pressure interlock is provide.

 Bottle Inspection System

SOFTWARE FEATURE'S
 Bottle Inspection System

Live view of all the 11 cameras is provided.

Result history of the last 100 bottles is displayed, on the inspection
screen.
Easy to define tolerances allow the user to decide which bottles need
to be passed and which need to be rejected.
Statistics of total bottle count and reject bottle percentage is displayed
on the screen.
In a few simple steps the users can, easily add/teach a new product to the
software.
The system changes over quickly to inspect new products. Changeover,
involves simply selecting the required product from the system library using
the touch screen.

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 Bottle Inspection System

The system has password protected user access levels for Operator,
Supervisor and Administrator.

Periodic reports are generated which can be accessed remotely.

Remote support can be provided, Optomech can remotely access the

systems and provide online support.
 Bottle Inspection System

INSPECTION
The main inspection screen shows the
live images from all 11 cameras, as the
bottles are being inspected.
large red LED’s light up, as soon as a
‘bad’ bottle is detected
Inspection history:
The area to the right of the viewing area shows the
inspection history, which is used to display the
defect status of the last 100 currently inspected
products.
Every defect is displayed with a red bar, and every
good bottle with a green bar.
With the help of this inspection history we can know
if a problem is repeating, Eg: if every 12 th product is
bad , and we have a 12 cavity mold in such a
situation we can know that there is a problem in one
of the cavities .

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 Bottle Inspection System

A product is the sum of all settings that are

required to test a specific type of object. Loading
a product causes all parameters to assume the
values that have been stored with this product.
The system maintains a database of products and
allows you to switch easily between any of them.
One of the main tasks of a quality inspection
system is the visualization of the current quality
level of production.
Statistics display provides a graphical display of
the recent past (last 100) and lets you analyze
quality problems with the push of a button.

There are 3 user access levels, ‘User’,

‘Supervisor’ & ‘Administrator .

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 Bottle Inspection System

Create New product

Any number of new products can be created, the

process of creating a new product is as follows

Enter a unique name for the product.

Pass a few bottles through the system.
Draw the Area of interest in any one of the
bottle.
Test and define the parameters for
acceptance/rejection of the product.

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 Bottle Inspection System

PARAMETERS
Image analysis algorithms process the image inside
the area of interest.
The Following are isolated and measured.
Surface defects like spots.
Color shade.
Neck Flash.
Optionally
Neck Blockage.
Top diameter.
Ovality.
Parting line defects.
Bottle bottom defects.

The user can set the permissible limit for each of the
above
any deviation above the permissible limit is
considered as a ‘bad’ product and ejected.
Any defect detected which is below the permissible
limit set by the user is considered ‘good’ product
and is not ejected. 29
 Bottle Inspection System

REPORTING
The inspection results are stored in the database
product wise.
The user can at anytime select the product and a
start and end date.
The software will generate reports on the
Number of bottles inspected per shift
Number of defective bottles per shift
Number of defective bottles per shift classified
as per the following defect classes.
Surface defects, Neck flash, Color shade
variation, Molding inside the mouth, Diameter /
Ovality.
Die Line, Bottle width variation, Bottle Height
variation, neck diameter variation.

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 Bottle Inspection System

The software can also be configured to

generate hourly reports of last one hour
production. of the currently running product.
These Reports can be exported over the
network and accessed remotely.
The generated reports can be exported to
excel.
Visual representation of the defects in the form
of a bar chart is provided, in addition to the
statistics data.
The photos of the defective bottles are stored
in the database, they can be recalled for review
anytime in the future.

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 Bottle Inspection System

Reports generated
from Specified Date
and time to defined
Date and time.

Reports can exported

to excel and .CSV file
so that it can be
incorporated in ERP.
 Bottle Inspection System

Reports generated
from Specified Date
and time to defined
Date and time.

Reports can exported

to excel and .CSV file
so that it can be
incorporated in ERP.
MACHINE MAINTENANCE
 Maintenance Component requiring Remarks/device
interval maintenance
Clean the conveyor belt Clean with a cloth
Clean area around the belt near the Clean with compressed air, and
Weekly rollers. brush.
Clean Photo Sensors optical
Windows
Monthly Clean filter insert in control cabinet Clean with oil free compressed
and replace, if necessary air.
Clean Photo Sensors optical Clean using IPA on cloth
Windows.
Once in 6 months Clean the lens Clean with Blower first, then
with brush and later Spray
Change the lights if they are dim liquid on Microfiber Cloth and
Change the Battery in the UPS, if it is clean the lens
Once in a Year not giving Backup.
MACHINE RUNNING COST
Power : AC Single phase 230V, 50 Hz

Power Consumption : 480 watts

Compressed Air : 4 to 6 bar,

Air Consumption : 0.00036 CFM per bottle ejected.

 Cost of typical
spares.
BIS-XL Spare Parts List
S.No Description Amount
1 Uninterrupted power Supply 14,900
2 Spot Light
1,500.00
3 Flat Belt
2,400.00
4 Rubber Roller
8,900.00
Side Conveyor Belt for BIS 1380X60X2
5 3,300.00
LED Surface Lights for BIS
6 4,500.00

7. Solenoid Coil for ejector 1,235.00

 Bottle Inspection System

Machine Layout BIS

XL

Fully extended Minimum height

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 Bottle Inspection System

For Further Details

Contact

Amit Garg
Director and Project Leader
Vision Products Division

Optomech Engineers Pvt Ltd

3A Type II, Prashanthi Nagar,
I.E. , Kukatpally, Hyderabad - 72
Ph: 91-40-23078371
E-mail : [email protected]
Web : www.optomech.in
Skype: optomechengineers

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