1. When size goes down and power goes up, performance benefits. Due to miniaturization and advances in the power of digital signal processors (DSP), imaging sensors, and decoding algorithms, traceability applications such as ID code reading, text verification, label inspection, and mark quality assessment can now be accomplished more economically by inspection systems.
2. New requirements are driving new technology. Facing increased regulations in the coming years to fight counterfeiting and improve food and drug safety, major pharmaceutical and food manufacturers have put traceability at the top of their agenda. Most of them uniquely code each lot or batch to identify time and location of production to make recalls more efficient and less costly. But this is not sufficient to meet the increased regulations of the future that will involve traceability, serialization, and authentication requirements.
Whether implementing traceability at the batch level or using serialized packaging to support full traceability (for initiatives such as e-pedigree in the pharmaceutical industry or other regulatory requirements), producers must deploy a broad range of technology and software platforms, spanning all levels, processes, and systems. At the highest levels, enterprise systems typically interface between the supply chain and plant-level systems; at the machine level, inspection system technology is used for applications such as bar-code reading, text verification, mark quality assessment, label inspection, and general machine vision functions. Beyond supporting compliance, producers are discovering that inspection systems deliver value in being able to stop counterfeiting, prevent parallel trade through unauthorized channels, and achieve greater visibility into how products are made, distributed, and used across supply and value chains.
In the CPG sector, suppliers are adding to this momentum. General Mills, Sara Lee, ConAgra Foods, Kraft Foods, and other major consumers of food packaging have formed the Food Safety Alliance for Packaging (FSAP). This consortium seeks to minimize mislabeling and is largely focusing its efforts on suppliers of labels and direct-print food-contact materials such as carton board and plastic films.
3. The use of vision technology is spreading. Vision is being used in more places throughout the manufacturing process, particularly with the application of small, distributed cameras. By using vision throughout the production process, problems can be identified at the source, reducing waste and cost while improving response time. A snapshot of today’s applications includes:
• Confirming package and product match, lowering risk of recall
• Reducing scrap by detecting wrong or mislabeled products early in production
• Checking for torn or missing labels
• Reading 1D and 2D bar codes, enabling track-and-trace
• Verifying print integrity, ensuring brand imaging on store displays
• Detecting products damaged in operations such as cartoning
• Checking date code presence
• Ensuring that ink-jet printers are functioning properly
• Performing date and lot code OCR and OCV, verifying that product information is correctly printed, and that labels are placed on the right products
• Providing guidance for robotic actuators
• Gauging
• Checking for roundness and conformity
• Providing shape-based orientation
