KHS uses artificial intelligence to optimise inspection technology

KHS is using artificial intelligence (AI) to solve the issues of the variety of closure alternatives and the increased demands on inspection technologies since tethered caps have been required for all single-use PET bottles in the EU since July 2024.

The solutions supplier has added AI-based fault identification to its well-proven Innocheck TSI closing inspection system.

The mandatory introduction of tethered caps had far-reaching consequences for bottle and beverage producers in the EU. They had to develop new solutions to continue meeting the high standards of product quality and product protection.

Inspection technology was also affected, as Nikita Wall, product support for labelling & inspection technology at KHS, explains: “Tethered caps were hardly in circulation before the EU requirement. Conventional systems therefore often reach their limits when it comes to cap inspection.” Furthermore, the high variety of bottle and cap design and increasing line outputs pose additional challenges.

With AI-based defect detection for tethered caps, the Dortmund-based full-service provider now offers a smart solution for identifying potential defects in cap inspection. The system uses patent-pending, advanced algorithms to analyse images of bottle caps in real time. Cameras capture the caps in high-resolution quality, while AI models evaluate this data. Using deep learning, the models adapt to new defect patterns.

The AI-supported solution thus increases both accuracy and efficiency during inspection.

“Our customers have very high demands on quality assurance. In intensive field tests, our AI-based defect detection has proven that it fully meets these high requirements,” Wall adds.

KHS developed the new system specifically for its Innocheck TSI closure inspection system. Implementation is possible on both new and existing machines.

KHS also plans to use AI in other inspection technology solutions in the future: “We are currently discussing in the development team which systems it makes sense to use. AI solutions only make sense when the requirements are complex and they offer our customers clear advantages,” Wall emphasises.