Bevarage Cap Inspection systems
1.Using self-developed hardware detection system, the fastest processing speed ,is up to 50000 BPH
2.The automatic elimination device is adopted to eliminate the bottle which is dificult to be poured
3.Using a high life LEDlight source, energy saving, environmental protection
I. Project Equipment Overview
Project Name: PET Bottle Cap, Anti-theft Ring, Liquid Level, and Inkjet Printing Inspection System
Scope: Automated online inspection and rejection of PET bottles with defects in caps, anti-theft rings, liquid levels, or inkjet printing.
Maximum Capacity: Up to 60,000 bottles/hour
Bottle Type: Glass bottles
Volume Range: 200 ml – 2 L
II. Operating Environment
Altitude: 5–3000 m above sea level
Temperature: 5°C – 40°C
Humidity: 50% – 65% RH
Factory Requirements: Floor flatness, load-bearing capacity, and related conditions must comply with national standards to ensure reliable machine operation.
Storage: After delivery, all equipment and spare parts must be stored in compliance with national standards. During storage, lubrication and routine maintenance are required to prevent corrosion, deformation, or other damage that may affect installation, commissioning, and performance.
III. Equipment Operating Conditions
Power Supply: 220V, 50Hz, single-phase (provided by customer; non-standard voltage requirements must be confirmed in advance, as they may impact specifications, delivery, and cost).
Total Power Consumption: Approx. 2.4 kW
Control Voltage: 24 VDC
Compressed Air: 4–12 Pa (pipeline from air source to equipment supplied by customer).
IV. Equipment Description
Installation: Mounted directly on the bottle conveyor for continuous inspection and rejection.
Inspection Scope:
Missing cap
High/raised cap
Crooked cap
Broken anti-theft ring
Low liquid level
Missing inkjet code
Excessive inkjet printing
Detection Principle:
As bottles pass the positioning sensor, the control unit records the bottle ID and encoder signal.
The sensor triggers the camera system, which captures images of the cap, liquid level, and inkjet printing. The images are analyzed by the processor, with results displayed on the HMI in real time and transmitted to the PLC for rejection logic.
If a defect is identified, the control unit activates the rejector to automatically remove the corresponding defective bottle.
4. Equipment mechanical components
model
| Name | Components | Functional Description | Remark
|
1 | Distribution cabinet | Composed of an image processor, an interface processor, a strobe controller, and a PLC. | Provides power to the entire system, processes images, and controls the rejection of defective products. | |
2 | Detection module | LED light source, industrial CCD camera, and sensor. | Dynamically captures images of PET bottles. | |
3 | Rejection device | Main components include solenoid valves and mechanical components. | Receives signals and controls the rejection of defective products. |
5. Electrical composition of the equipment
model
| Name | Unit | Brand Notes | Quantity |
1 | Embedded imaging industrial computer (4 Ethernet ports) i5+4G+120G | Unit | Taiwan Chaoen, dust-proof, fast processing speed, and excellent stability | 1 |
2 | DAHUA high-speed gigabit digital camera | Unit | Resolution 680x480, imported from Canada, industry-leading brand | 4 |
3 | Camera I/O module | Set | Made-in-China | 4 |
4 | Lens | Piece | COMPUTAR 6MP, 12mm | 4 |
5 | Camera-50/30line cable | Piece | Made-in-China, 5m | 4 |
6 | MW.24v DC power supply 75/120W (DRP-75/120-24) | Piece | Taiwan Mean Well | 2 |
7 | PLC | Piece | Maotong independently developed | 1 |
8 | Touchscreen display | Piece | Taiwan IEI 15-inch | 1 |
9 | Light source controller | Unit | Customized in China, 4-way asynchronous triggering, screen flicker control technology, significantly extending light source life | 1 |
10 | Photo light source | Unit | Customized surface lighting, infrared, and blue | 4 |
11 | Power distribution cabinet | Piece | Made-in-China, 304 material, brushed, pickled, oxidized, and brushed finishes | 1 |
12 | Single-stage rejector Mono | Piece | Customized, air-push type, 304 material | 1 |
13 | Reject unit cylinder | Piece | Norgren high-speed cylinder, UK | 1 |
14 | Reject unit solenoid valve | Piece | MAC high-speed solenoid valve, US, 4.9ms response speed | 1 |
15 | Encoder | Piece | Made-in-China, Hode, incremental type | 1 |
16 | Low-voltage electrical components | Piece | Schneider, France | Several |
17 | Image processing system | Piece | Maotong independently developed, can develop V3.0 according to customer needs | 1 |
18 | Special equipment refrigeration unit - industrial air conditioner | Piece | Shanghai Highly Special, cooling capacity 320W | 1 |
19 | Terminal blocks | Piece | Honeywell, USA | Several |
20 | Photoelectric sensor | Piece | Leuze, Aurora PNP | 1 |
21 | Other electrical components | Piece | - | Several |
22 | Cabinet material and surface treatment | Piece | 304 material, igus® mechanical parts, brushed, pickled, oxidized, and brushed finishes. | 1 |
23 | Alarm light | - | Several | |
24 | Oil-water separator | - | Schneider tri-color tower light | Several |
25 | Relay | Piece | 1 | |
26 | Glass material | Piece | AirTac | 1 |
7. Cap Inspection
This module integrates three CCD cameras positioned at different angles to minimize blind spots and ensure comprehensive image capture. Equipped with specialized optical lenses, it effectively filters ambient light to enhance image clarity. The system is designed to identify cap-related defects, including missing caps, high/raised caps, tilted caps, and damaged caps.
8. Liquid Level Detection
A front-facing CCD camera is used to capture the liquid level of each bottle. When stationary, the liquid surface remains nearly horizontal, facilitating precise imaging. Through image processing, the region below the liquid level is displayed as black, while the area above is shown as white. A dedicated algorithm distinguishes whether the liquid level falls below or exceeds the specified threshold.
9. Inkjet Printing Inspection
This module employs a CCD camera to capture front-facing images of inkjet codes on both bottles and caps. The images are digitally processed to verify printing quality. Bottles with missing, blurred, or excessive inkjet markings are automatically identified and rejected. The system supports both yellow caps with black ink and black caps with white ink.
10. Detection accuracy
Inspection Items | Inspection Contents | Detection accuracy
| Rejection rate
|
| No cap | —— | ≥99.99% |
High cap | ＞0.8 mm | ≥99.98% | |
Crooked cap | ＞0.8 mm | ≥99.5% | |
Safety ring 100% disconnected | ＞1mm gap | ≥99.99% | |
Safety ring >70% broken | ＞1mm gap | ≥98.32% | |
Safety ring >50% broken | ＞1mm gap | ≥95.78% | |
Safety ring 100% missing | —— | ≥99.99% | |
Safety ring 70% missing | —— | ≥98.21% | |
Safety ring 50% missing | —— | ≥95.78% | |
Inspection Items | Liquid level detection (high and low) | 3mm below (or above) the standard
| ≥99.92% |
Bottle Cap Inspection | No inkjet print | ≥99.99% | |
Overall inkjet print 50% missing | ≥99.95% | ||
Overall inkjet print 30% missing | ≥99.9% | ||
Overall inkjet print 20% missing | ≥99.8% | ||
Inkjet print is blurred enough to remove the inkjet characters after processing | ≥99.99% |
