Automated Package & Label Defect Inspection on High- Speed Conveyor Lines
A high-volume consumer packaged goods (CPG) facility producing 120,000 packaged food items daily across 6 high-speed conveyor lines.
Run on Arjuna · Plant Operations & Safety
The challenge
Packaging defects (missing cap seals, crushed boxes, misaligned barcode labels) slipped past human visual inspectors at line speeds of 300 units/minute.
Defective products reached retail customer shelves, causing expensive retailer chargeback fines and product returns.
Installing proprietary inline vision inspection hardware required stopping production lines for weeks.
How Arjuna solves it
High-Speed Overhead CCTV Integration
Arjuna ingests high-frame-rate video feeds from standard industrial cameras positioned over existing conveyor lines.
Sub-Millimeter Defect Detection
Detects missing cap seals, torn labels, crushed cardboard edges, and unreadable barcodes at full line speeds.
Automated Pneumatic Reject Arm Interlocking
Triggers sub-second signal outputs to pneumatic reject arms to kick defective items off the line instantly.
Real-Time Defect Categorization
Categorizes defect types (seal vs label vs box damage) in real time, alerting maintenance leads to specific machinery misalignments.
Line Quality Yield Dashboard
Displays live defect percentages and line yield metrics on operator shop-floor screens.
The outcome
- annual retailer chargeback penalties and product return costs
- $0annual retailer chargeback penalties and product return costs
Defective package escapes to retail customers reduced to zero.
Saved $450,000 in annual retailer chargeback penalties and product return costs.
Retrofit installation completed over a single weekend without disrupting production schedules.
Representative scenario: a modelled industry situation showing how this accelerator applies. Figures are projections, not a named client result.
Capabilities used
Every accelerator is assembled from the same capability layer, so a workflow you adopt here shares its foundation with the rest of the portfolio.
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