Manual taping inspection on a 40 CPM case former means a human has to catch a mis-sealed carton every 1.5 seconds — an impossible standard. At that rate a skewed tape, open flap or wrong label is missed constantly. ZRAY now fits its high-speed case formers with a machine-vision station that checks 100% of cases at line speed, so defects are rejected before they reach the palletiser. Built around a 5 MP camera at 60 fps with Cognex / Keyence optics, it rejects non-conforming cases with a pneumatic arm while archiving every NG image for 90 days.

Vision System Configuration

Inspection Items and Acceptance Criteria

Each case is photographed at the forming exit; the image is compared against the active recipe, and any deviation beyond the table above drives a reject signal.

Reject and Traceability

A pneumatic reject arm diverts the NG case to a dedicated buffer position, keeping it out of the good stream. Every NG image is stamped with the batch number and, where available, pushed to the MES, so a quality auditor can trace a defect back to a specific run and shift. Image archives are retained for 90 days to support customer complaints and internal CAPA.

False-Reject Control

A system rejecting good cases is as costly as one missing bad ones. ZRAY holds false rejects to ≤ 0.3% via stable enclosed lighting, periodic grey-scale calibration and a weekly operator-reviewed self-learning step as board lots change.

Link with the Palletiser

When the reject rate crosses a set threshold, the former can hold the upstream infeed and signal the palletiser to pause, preventing a pile of suspect cases at the end of the line. This interlock is configured in the PLC and tuned per product.

Camera Calibration and Maintenance

Field Alarm Codes

Model Selection and Support

For lines above 500 000 cases per year, our Double-Head High-Speed Case Former integrates the vision station as standard and sustains 40 CPM with full inspection. For commissioning, spare lenses and calibration support, visit ZRAY Support.

Get a Quotation for Your Packaging Line

Send us your carton size range, board grade and required CPM — our engineers will return a model recommendation, layout drawing and quotation within 24 hours.

Contact ZRAY: [email protected] · WhatsApp +86 13681839278