Folding Carton Vision
Inspection & Defect
Containment

• Folding Carton Vision Inspection: Captures and evaluates defined carton attributes before the blank enters downstream folding, gluing.
• Controlled Carton Feeding: Separates and presents flat carton blanks consistently for transport and inspection.
• Stabilized Transport: Maintains carton position through the imaging area to support repeatable image capture and controlled movement.
• Controlled Illumination: Establishes consistent imaging conditions across printed, coated, reflective, embossed, foiled, and variable carton surfaces.
• Print and Artwork Inspection: Identifies configured conditions such as missing print, artwork deviations, registration shifts, colour variation, marks, contamination, and incomplete printed elements.
• Code and Data Verification: Supports inspection of configured 1D codes, 2D codes, static text, variable data, serial numbers, and job identifiers.
• Recipe-Based Inspection: Stores inspection regions, tolerances, thresholds, and job criteria for repeatable production setup.

• Defect Decision Logic: Evaluates detected conditions against the active recipe and determines whether each carton continues or is diverted.
• Pack-Smart Bridge Module: Replaces the standard outfeed in an inline installation and connects the inspection system to existing folder-gluer or downstream equipment.
• Integrated Divert Handling: Removes non-conforming cartons after inspection and before they enter downstream production.
• Controlled Downstream Transfer: Maintains the accepted carton path from the vision inspection system into the existing line.
• Touchscreen HMI: Provides operator access to system setup, recipe selection, inspection controls, diagnostics, alarms, and defect review.
• Modular System Architecture: Allows feeding, transport, inspection, bridge transfer, divert handling, controls, and downstream interfaces to be configured around the application.
• Production Data Integration: Configured systems can connect inspection events, reject activity, defect records, and reporting with Pack-Smart production-data tools.

• Primary Application: Inspection of flat folding carton blanks.
• System Type: Modular folding carton vision inspection system.
• Primary Installation: Inline ahead of existing folder-gluer equipment.
• Product Condition: Printed and converted carton blanks before folding and gluing.
• Inspection Position: After controlled feeding and stabilization, before downstream value-added production.
• Inspection Coverage: Print, artwork, registration, colour, surface, orientation, code, text, and variable-data inspection according to the configured system.
• Material Handling: Controlled carton feeding and stabilized conveyor transport through the inspection area.
• Integration Architecture: Pack-Smart bridge module installed between the vision inspection enclosure and the existing downstream equipment.
• Reject Position: Divert handling located after inspection and before the folder-gluer.
• Accepted-Product Path: Accepted cartons transfer through the bridge into the downstream production process.
• Downstream Interface: Configured around the height, direction, controls, speed, product path, and operating requirements of the existing equipment.

• Operator Interface: Touchscreen HMI with job control, recipe management, diagnostics, status monitoring, and defect review.
• Data and Reporting: Configurable inspection-event logging, defect history, reject records, images, and job reporting.
• Maximum Production Speed: 350 m/min
• Maximum Throughput: 60,000 PPH
• Minimum and Maximum Carton Dimensions: Length (parallel to travel direction): 90 mm to 650 mm, Width (perpendicular to travel direction): 90 mm to 500 mm
• Supported Paperboard Range: 90 to 350 gsm
• Camera Resolution and Configuration: 8K resolution color line scan camera
• Electrical Requirements: 3 Phase 220 V 60 Hz
• Pneumatic Requirements: 0.8 to 1.0 Mpa, 0.3 to 3 m³/min
• System Footprint: 6.5 m (length) x 1.85 m (width) x 1.5 m (height)

Controlled Carton Feeding

• Flat carton blanks are loaded into the feeder and separated for continuous presentation to the inspection system.
  
• The feeding process establishes the spacing and transfer conditions required for controlled movement through the inspection workflow.

Alignment and Stabilized Transport

• Cartons are guided and stabilized as they move toward the vision inspection enclosure.
  
• Controlled transport helps preserve carton position and image consistency through the configured inspection area.

Vision Inspection Enclosure

• Each carton enters a controlled imaging environment containing the configured cameras, optics, lighting, sensors, and image-processing components.
  
• The system captures defined carton regions and evaluates them against the active job criteria.

Pack-Smart Bridge Module

• A Pack-Smart-engineered bridge module is installed between the inspection enclosure and the existing folder-gluer equipment.
  
• The bridge supports the physical transfer, product path, and system interface required by the downstream production environment.

Integrated Divert Gate

• The bridge module contains the vision-controlled divert technology.
  
• When the inspection system identifies a non-conforming carton, the resulting signal triggers the divert action before the carton reaches downstream production.

Downstream Transfer

• Accepted carton blanks continue through the bridge and enter the existing folder-gluer line.
  
• The downstream equipment then performs its normal folding, gluing, finishing, packing, or delivery process.

Print and Artwork Inspection
Configured inspection regions can identify conditions such as:

• Missing print
• Incorrect graphics
• Registration deviation
• Colour variation
• Spots or contamination
• Scratches and surface marks
• Broken or incomplete printed elements
• Mixed cartons
• Wrong-job artwork
• Incorrect orientation

Code and Data Verification
Configured inspection tools can evaluate:

• 1D barcodes
• QR codes
• Data Matrix codes
• Static printed fields
• Variable data
• Serial numbers
• Product identifiers
• Job-specific text

Inspection capability depends on the selected cameras, optics, software, code type, print quality, carton surface, and application requirements.

Surface Inspection

• Controlled lighting and image processing support inspection across printed, coated, reflective, embossed, foiled, and otherwise finished carton surfaces.
  
• The configured inspection criteria determine which surface conditions are identified and how they are classified.

Inspection Decision Logic

• Each detected condition is evaluated against the tolerances and thresholds assigned to the active job recipe.
  
• The inspection result determines whether the carton continues into downstream production or is removed through the bridge-mounted divert system.

Reject Handling

• Non-conforming cartons are diverted after vision inspection and before reaching the folder-gluer or pack-out equipment.
  
• This prevents known defects from consuming adhesive, finishing time, packing materials, operator attention, or downstream machine capacity.

Defect Review

• Operators can review available defect images, inspection regions, classifications, and job conditions through the configured inspection interface.
  
• This provides more useful production information than a pass-or-fail signal alone.

Inspection History

• Configured systems can retain inspection events, defect images, reject records, and associated job information for later retrieval and review.
  
• This creates a clearer production record of what the system inspected, what it identified, and how each exception was handled.

Production Reporting

• Available reports can support job review, defect analysis, production reconciliation, setup validation, and continuous process improvement.

Delta-X Trust Integration

• When included in the final system configuration, Delta-X Trust can connect inspection events, reject activity, job information, and production records within a governed Pack-Smart data environment.
  
• This extends inspection beyond the immediate machine decision by making production information available for review, reconciliation, and broader operational visibility.

System Motion Control

• The system controller coordinates carton feeding, transport, sensor feedback, inspection timing, bridge transfer, and divert execution.
  
• The control architecture is configured around the required product flow and downstream operating conditions.

Inspection Software
The configured inspection environment manages:

• Image capture
• Inspection regions
• Reference criteria
• Defect thresholds
• Classification rules
• Pass-or-divert decisions
• Reject signals
• Defect images
• Job information
• Available reporting functions

Touchscreen HMI
The operator interface provides access to:

• Job and recipe selection
• System setup
• Inspection thresholds
• Sensitivity controls
• Production status
• Alarm conditions
• Diagnostics
• Defect review
• Reporting