Thermal Bottle Cap Seal Inspection Solution

Take Quality Control to the Next Level

Are you currently facing challenges with bottle cap quality control that could impact your brand’s reputation? At MoviTHERM, we specialize in ensuring the quality of bottle cap seals. Our automated thermal seal inspection solution eliminates the risk of compromised product integrity. Say goodbye to improper sealed containers that can lead to customer dissatisfaction. Deliver perfect products with confidence and peace of mind.

Improve Seal Quality

Increase Efficiency

Reduce Waste

Protect Brand Reputation

Ensure Defect-Free Bottle Cap Seals

Are you facing difficulties with expensive and time-consuming quality control procedures for bottle cap seals? MoviTHERM has the perfect solution for you. Our thermal inspection system for bottle cap seals is specifically designed to identify and prevent defects in heat-sealed packaging during the production process.

Our automated system is seamlessly integrated into your current production line, removing the need for manual inspection and reducing the possibility of human error. By using our solution, you can improve efficiency, maintain a streamlined production flow, and achieve greater productivity levels, all while ensuring precise and reliable results.

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MoviTHERM Thermal Seal Inspection System

How does the system work?

MoviTHERM’s thermal seal inspection system uses infrared cameras to “see” the residual heat from thermal-based sealing processes. Characterizing a good seal by the temperature profile allows the system to reliably detect good and bad seals.

  • Uses high-performance infrared cameras for non-contact temperature measurement with thermal imagery.

  • Touch-screen PC with application-specific software and GUI interface packaged in a standard powder-coated industrial electrical enclosure.
  • Interactive inspection Recipe Programmer to accommodate multiple products – or to try different “what-if” scenarios.
  • Robust bi-directional PLC interface to transfer status messages and PASS/FAIL results to a plant PLC (Ethernet/IP or Modbus).
  • Image FTP to transfer fault images to a remote server for offline review.

Type of Defects That Can Be Detected

  • Incomplete Seals
  • Seal Contamination
  • Improper Adhesion
  • Seal Misalignment
  • Seal Cracks or Breaks
  • Seal Irregularities
  • Inconsistent Cap Torque
  • Missing Cap or Seal Foil

Benefits of Using Thermal Seal Inspection

  • Thermal imaging allows for non-destructive testing, which means that products can be inspected without damaging them.
  • Infrared cameras can “see” residual heat from sealing processes, making it easier to detect defects.
  • Thermal imaging is a fast and efficient method of inspection, as it can assess multiple seals simultaneously.
  • By automating the inspection process with thermal imaging, the need for manual inspection is eliminated, reducing the risk of human error.
  • Thermal imaging provides real-time feedback and reporting on the quality of packaging products, enabling producers to quickly identify and correct any issues that arise.

Overview of the System

1 - Main Area Viewing Functions 2 - Main Viewing Area 3 - Inspection Zone 4 - Color Palette Selector 5 - Image Snapshot 6 - Seal Scores History Plot 7 - System Status 8 - Pass/Fail Indication 9 - Seal Profiles 10 - System Settings 11 - Evaluation Metrics

Ready to improve your quality control process?

Contact us today and say goodbye to improperly sealed bottle-caps. 

Helpful Resources

Induction Seal vs Heat Seal

Induction Seal vs Heat Seal: What’s the difference?

In this article, we break things down to compare the benefits and challenges of an induction seal vs a heat seal.

types of packages that can be detected using thermal imaging

Types of Packages You Can Inspect with Thermal Imaging

Learn about the different types of packaging that can be inspected with thermal imaging for seal quality

Improve Packaging Line Efficiency

Improve Packaging Line Efficiency with Thermography

A more efficient packaging line can lead to reduced costs, improved productivity, and increased customer satisfaction.

Thermal Seal Inspection Guidebook

A Comprehensive Guide to Ensuring Product Integrity

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FAQ

Thermal Cameras
Controller, Wall-mount
Enclosure, Panel PC with Touchscreen
All necessary support electronics, power supply, and cabling
Application software

All that is required for the installation is standard 110VAC/15A power, one Ethernet cable to each camera, and the I/O connections. The cameras are powered over Ethernet (PoE), which makes installation very convenient. No additional camera power supplies or cables are required.

Absolutely! In fact, we recommend hiring MoviTHERM for the commissioning and training phase of the system deployment. Nobody knows our systems better than we. We design and build them! Additionally, you gain access to thermography experts to assure that you achieve the best return on investment.

Some of the defects that can be identified using this inspection method include:

Incomplete Seals: Thermal inspection can detect areas where the seal is not properly formed or lacks sufficient adhesion, leading to potential leakage or compromised product integrity.
Seal Contamination: The system can identify instances where foreign particles or contaminants are present on the seal surface, which can pose a risk of product contamination.
Improper Adhesion: Thermal inspection can detect areas where the seal has not adhered properly to the container or bottle, indicating a potential weakness in the seal’s strength.
Seal Misalignment: The system can identify situations where the seal is not properly aligned or positioned, resulting in an uneven or imperfect seal.
Seal Cracks or Breaks: Thermal inspection can detect cracks or breaks in the seal that may compromise its integrity and allow for the entry of air or contaminants.
Seal Irregularities: The system can identify irregularities in the seal’s shape or width, ensuring consistency and uniformity.
Inconsistent Cap Torque: When a cap is inadequately tightened on a bottle, there is insufficient pressure to form a quality seal. This appears as areas of lower and higher temperatures around the perimeter of the seal, which can be identified by the inspection system.
Missing Cap or Seal Foil: If a cap is missing completely, or the seal foil is missing, the thermal camera can easily detect these irregularities.
Incorrectly Configured Sealing Process: If the sealing equipment is not operating in the optimal sealing range, this can be identified by higher or lower than normal temperatures in the seal. The inspection system can reliably identify any changes to the seal temperature that may lead to missing or incomplete seals (under-power faults), or seal/cap burning (over-power faults).

Yes, the thermal inspection system can be integrated into existing production lines. It is designed to seamlessly integrate with the production process, allowing for efficient and automated quality control.

The thermal inspection system can be synchronized with other equipment and machinery in the production line, such as conveyors, sensors, or control systems. It can communicate with the plant’s PLC (Programmable Logic Controller) or other control devices to transfer status messages, PASS/FAIL results, or trigger actions based on inspection outcomes.

The inspection speed of the system can vary depending on factors such as the specific model, configuration, and the complexity of the inspection requirements. Typically, thermal inspection systems are designed to operate at high speeds to keep up with the production line’s pace.

The exact inspection speed can be influenced by factors such as the size and design of the product, the conveyor speed, and the complexity of the inspection criteria. As part of the pre-engineering engagement, MoviTHERM works through all the technical aspects to arrive at an expected throughput number that is consistent with the physical realities and constraints.

Using thermal inspection offers several benefits compared to other inspection methods. Here are some advantages:

Non-contact Inspection: Thermal inspection is a non-contact method, meaning it does not require physical contact with the bottle caps. This eliminates the risk of damage or alteration to the caps during the inspection process.
Real-time Detection: Thermal inspection provides real-time feedback on the seal integrity of bottle caps. Defects such as incomplete seals or seal contamination can be immediately identified, allowing for prompt corrective actions.
High Accuracy: Thermal inspection systems use advanced infrared cameras and algorithms to accurately detect temperature variations. This enables precise identification of seal defects, ensuring reliable inspection results.
Speed and Efficiency: Thermal inspection can be conducted at high speeds, keeping up with the pace of production lines. It enables efficient and continuous inspection without slowing down the manufacturing process.
Comprehensive Coverage: Thermal inspection can assess the entire seal area of bottle caps in a single image, providing a comprehensive analysis. It can detect defects across the entire circumference of the cap, ensuring thorough inspection and minimizing the chances of undetected issues.
Automation and Integration: Thermal inspection systems can be seamlessly integrated into existing production lines, automating the inspection process. This reduces reliance on manual labor and enhances overall efficiency.

By leveraging these benefits, thermal inspection provides manufacturers with a reliable and efficient method to ensure seal integrity, minimize defects, and maintain high-quality standards.