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Online Leak Detection System for Induction-Sealed Bottles
Induction cap sealing is widely adopted across various industries including pharmaceuticals, food and beverages, cosmetics, detergents, disinfectants, and agrochemicals. Ensuring the seal integrity of each bottle is a critical quality control step especially for products that are sensitive, hazardous, or regulated.
Why Seal Inspection Matters
Poorly sealed bottles can lead to:
- Leakage and contamination
- Product degradation
- Regulatory non-compliance
- Health and environmental hazards (especially for pesticides or chemicals)
Common Causes of Seal Defects
- Insufficient power from the induction sealer
- Incorrect conveyor speed
- Improper coil height or cap torque
- Incompatible liners or bottle materials
- Surface treatment issues (e.g. flame-treated necks)
Our Solution: AI + Thermal Vision
The Multipack Induction Cap Seal Integrity Inspection Machine uses advanced thermal imaging combined with AI-powered vision analysis software to inspect every bottle non-invasively and in real-time.
How It Works:
- A high-grade thermal imaging camera captures the heat signature of the sealed cap.
- Our AI-based software analyzes the thermal profile to identify sealing defects.
- Faulty bottles are automatically rejected from the line and collected for review or rework.
System Features
- Real-time, 100% online inspection of every bottle
- Deep learning algorithm trained to detect a wide range of defects
- Auto-rejection of defective bottles
- Compatible with existing conveyor lines
- Non-invasive, contactless inspection
- Data storage and traceability for audit and quality review
Defects Detected
Cap-Related:
- No cap
- Loose or high cap
- Tilted cap
Seal-Related:
- No seal
- Seal placed in reverse
- Partial seal
- Moon cut or incomplete seal
- Warped or folded seal
- Under-heated (weak) seal
- Over-heated (burned) seal
Thermal profiles of both good and defective seals are visually displayed in the system interface for instant operator feedback.
Defects Detected
| Parameter | Description |
| Inspection Speed | Up to 300 bottles/min |
| Bottle Types | HDPE, glass |
| Bottle Shapes/Sizes | Unlimited |
| Cap Diameter Range | 20–200 mm |
| Applicable Cap Types | CT caps, tip caps, single-layer caps |
| Detection Accuracy | Avg. 99.6% |
| Integration | Inline with standard conveyor systems |
| Rejection System | Automated eject to rejection bin |
| Data Logging | Full inspection data history & export |
| Warranty | 1-year limited |
Industries Served
- Pharmaceuticals
- Food & Beverage
- Cosmetics & Personal Care
- Chemicals & Detergents
- Agricultural Products (e.g., Pesticides)
