Biscuit Package Inspector
Automated dual-inspection system that reduces secondary packaging defects by 99% through computer vision and weight verification on a live production line.
The Problem
The production line was experiencing a significant rate of incorrectly packaged biscuit products reaching secondary packaging — products with wrong piece counts or faulty seals were making it through undetected, causing waste, rework, and customer quality issues.
The Solution
I designed and implemented an automated dual-inspection station integrated directly into the production line. The system performs two independent inspections on every package before it advances:
- Weight inspection via check weigher to verify the correct number of biscuit pieces per package
- Vision inspection using a Cognex InSight 2800 camera to detect seal integrity and identify packages stuck together or improperly closed
The Cognex camera was configured with a custom detection model. It communicates directly with a Siemens S7-1500 PLC, which controls pneumatic rejection cylinders that physically eject non-conforming packages from the line in real time.
Safety
The station is equipped with LED safety light curtains on all access points, ensuring operator safety during line operation. The PLC controls all safety interlocks in compliance with plant safety standards.
Results
- 99% reduction in defective packages reaching secondary packaging
- Automated rejection with zero manual intervention required
- Real-time feedback loop between vision system and PLC
- Full integration with existing production line infrastructure