Smarter control starts with precision
Precision That Keeps Production Moving
In high-speed bottling environments, even the smallest defect can have major consequences. A poorly sealed cap can lead to product leaks, contamination, or compliance issues, especially in pharmaceutical, nutraceutical, or beverage packaging. That’s why many manufacturers are turning to thermal imaging as a non-contact, real-time method to verify cap seal integrity.
At the heart of this solution is the Flir A6301, a powerful midwave infrared camera that, when integrated into moviTHERM’s Thermal Seal Inspection (TSI) system, delivers unmatched accuracy for identifying seal defects before they reach your customers.
Why the Flir A6301 Is Ideal for Heat-Sealed Caps
The Flir A6301 stands out for one simple reason: it captures fine temperature gradients that directly reflect seal quality. On bottling lines using CRC or flip-top caps, where caps must pass through an induction or heat-sealing process, this thermal precision is essential.
Key Advantages of the Flir A6301:
- Midwave infrared sensitivity (MWIR) that is ideal for applications where caps are momentarily heated and require fine temperature mapping.
- High-speed frame rates up to 60 Hz that keep up with bottling lines running over 400 feet per minute, capturing every bottle in motion.
- Radiometric accuracy that provides true temperature readings correlated to seal integrity.
- Industrial integration through GigE Vision and GenICam compatibility, allowing seamless communication with moviTHERM’s TSI software and PLC systems.This precision allows operators to identify underheated, overheated, or unevenly sealed caps before they cause downtime or product waste.
This precision allows operators to identify underheated, overheated, or unevenly sealed caps before they cause downtime or product waste.
Thermal Imaging vs. Traditional Inspection
Most bottling lines rely on visual or torque-based inspection systems, but these methods cannot detect what is happening beneath the surface of the cap. The Flir A6301 captures the heat distribution pattern left by the sealing process.
That means it can detect:
- Missing liners
- Double liners
- Overheated or underheated seals
- Improper folds or misaligned caps
- Loose or incomplete twists
By visualizing thermal uniformity, operators can fine-tune sealing pressure, temperature, or dwell time to maintain consistent quality across the entire line.
How moviTHERM’s TSI System Unlocks Its Full Potential
While the Flir A6301 provides the thermal data, the moviTHERM TSI system transforms it into actionable intelligence. The system automatically detects, classifies, and rejects defective caps in real time using customizable “recipes” that correspond to each bottle type or production run.
Together, they deliver:
- Real-time pass/fail analytics with visual overlays of each bottle’s seal.
- Automatic rejection signals for defective bottles, integrated directly into line controls.
- Comprehensive traceability with defect logs and temperature maps stored for QA audits.
- Predictive insights that help detect upstream issues such as heater drift, misaligned seal heads, or worn equipment before they cause rejects.
Fast Deployment, Minimal Downtime
Installing a thermal inspection system can sound intimidating, but moviTHERM’s solution is built for easy integration. Most customers are up and running within a single shift thanks to pre-calibrated camera setups, user-friendly software, and guided recipe loading. Once installed, operators can run continuous inspections with minimal maintenance, requiring only occasional lens cleaning and periodic calibration.
From Quality Control to Process Optimization
The combination of the Flir A6301 and moviTHERM’s TSI platform does more than catch defects. It helps reduce process variability and improve sealing consistency over time.
By visualizing thermal profiles across thousands of bottles, you gain a deeper understanding of how your line performs under different conditions. This turns inspection from a reactive quality gate into a preventive process control tool.
Conclusion: See What Others Can’t
In fast-moving bottling operations, the Flir A6301 delivers the precision, speed, and stability needed to keep quality on track. Integrated with moviTHERM’s TSI system, it ensures every seal is verified, every defect is caught, and every customer receives a product that meets your standards before it ever leaves the line.
About moviTHERM
moviTHERM – Advanced Thermography Solutions was founded in 1999. The company offers solutions for plastic welding, package sealing, and non-destructive testing. In addition, moviTHERM provides IoT Cloud monitoring solutions for thermal imaging applications for early fire detection, machine condition monitoring, and other applications. moviTHERM is a Teledyne Flir Premium Partner and master distributor for FLIR Thermal Cameras for automation and science applications.
