KHS Group has optimised its Innocheck TSI closure inspection unit with the implementation of an AI-based fault detector for tethered caps.
Tethered caps have been mandatory for all non-returnable PET bottles in the EU since 2024, which KHS said had “far-reaching consequences for bottle and beverage producers in the EU”, as they were now “forced to find new solutions to continue to meet the high demands made of product quality and protection”.
According to Nikita Wall, labelling and inspection technology product support at KHS, this also affected inspection technology.
“Tethered caps were rarely used before the EU directive came into force. Conventional systems thus frequently reach the limits of their capacity where cap inspection is concerned,” explained Wall.
“What’s more, the large number of bottle and cap design variants processed and increasing line capacities present additional challenges.”
With its AI-based fault detection system for tethered caps, the Dortmund turnkey supplier now provides smart engineering that identifies potential defects during cap inspection.
The new module makes use of patent-pending algorithms to analyse images of bottle closures in real-time. Cameras log the caps in high-resolution quality, while AI models evaluate this data. By applying deep learning, the models adjust to account for any new types of flaw found.
“KHS’ AI-assisted system increases both the accuracy and efficiency of inspection. Our customers make extremely high demands of quality assurance. In intensive field tests, our AI-based fault detector has proved that it fully meets these requirements,” emphasised Wall.
KHS has developed the new system to be easily implemented on both new and existing machines.
