Thermal inspection for bottle cap seal integrity

Ensure every bottle is leak‑free, tamper‑safe, and recall‑proof with real‑time thermal quality control.

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? Our thermal seal inspection system for bottle caps 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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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

How does the system work?

Thermal cameras scan each cap in real time, verifying seal integrity without slowing production. Defects like incomplete seals, misaligned caps, or thermal inconsistencies are flagged instantly—so your team can act before defective products leave your facility.

Smarter seal inspection, faster production

Automated thermal imaging verifies every cap instantly, without slowing your line.

100% Inline Inspection

No sampling, every bottle is checked.

Non-Contact Analysis

No risk of contamination or damage.

Immediate Defect Alerts

Reject bad seals in real time.

Comprehensive Seal Coverage

Entire seal area is inspected in one frame.

Data + Trend Reporting

Identify seal issues before they escalate.

Scalable & Fast

Keeps pace with high-speed production lines.

Getting started is easy

We’ll discuss your needs and design the right solution for your line.

Provide details or samples for evaluation so we can confirm system performance.

Your system arrives ready to install, with training to ensure confidence from day one.

Protect every seal, protect your brand.

Real-time seal verification keeps you compliant, efficient, and ahead of costly quality issues.

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
MoviTHERM Thermal Seal Inspection System

Seamlessly integrate with your production line

The TSI system is designed for effortless integration into your existing production line. It speaks the most common industrial languages, ensuring compatibility with your current setup. With a standard Ethernet/IP interface and built-in digital I/O for alerting and bottle rejection, the TSI system fits right in. For those requiring strict regulatory compliance, it also offers optional FDA CFR 21 Part 11 compliance for electronic records keeping.

Helpful resources

Thermal Seal Inspection Starter Guide

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

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.

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.

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.