📷[IMAGE] Real BIS/CIS machine on live production line · Defect detection overlays · Product-centric, not stock photography
40+Years of optical expertise
400+ CPMLines running with PLC integration
100%Product inspected — every unit, every shift
6 DaysAvg. installation & commissioning
Industries We Serve
Do You Recognise Your Production Challenge?
Each industry has its own defect profile, line constraints, and quality expectations. Click your industry to see the exact problems we solve — and the systems we use to solve them.
📄Case Study: Pharma Cap Supplier Passes FDA Vendor Audit After CIS Deployment
Zero defective caps in 10 months · CAPA closed within 90 days · FDA audit re-qualified
Read Case Study →
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FMCG & Personal Care
High-Speed Lines. Brand Identity. Every Defect is a Consumer Complaint.
One returned batch erases a quarter's profit margin. We stop defects before they leave the line.
Common Production Problems
Surface scratches, scuffs, and dents on bottles reaching retail
Cosmetic cap defects — cracked, short-moulded, oval — at 300–400 CPM
Label misalignment or skew that fails brand guidelines
Wrong artwork during multi-SKU changeovers on high-throughput lines
Induction seal failures causing leakage in transit
AQL sampling: 4,000–5,000 bottles uninspected per 30-minute window
📄Case Study: FMCG Bottle Maker Eliminates ₹28 Lakh Annual Customer Returns
BIS deployed on 4 lines in 6 days · 2.4M bottles/month · 100% inspection replacing AQL sampling
Read Case Study →
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Food & Beverage
Hygienic Packaging. Seal Integrity. Consumer Trust Built at Scale.
A broken induction seal or contaminated bottle in food isn't a factory problem — it's a headline.
Common Production Problems
Broken or under-heated induction seal — freshness breach and tamper-evidence failure
Cap leakage risk at high speed — especially edible oil and condiment lines
IML label mis-application or missing label on packaged goods
Contamination and foreign body detection in transparent containers
Bottle base and body defects causing instability on filling lines
Fill-level variation outside tolerance on regulated packaged goods
📄Case Study: Nutraceutical Brand Stops Hidden Seal Failures — 99.97% Seal Integrity
ISIVS detects under-heat seals invisible to visual inspection · ₹14L in returns eliminated
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Agrochemical & Chemical
Hazardous Contents. Label Accuracy is Not Optional. Leakage is Liability.
Incorrect labelling or an unsealed cap in agrochemical packaging creates regulatory and safety risk simultaneously.
Common Production Problems
Weak or missing induction seal on hazardous liquid containers
Cap not fully seated — leakage risk in transit and storage
Incorrect label for chemical formulation — regulatory non-compliance
Bottle crack, pinhole, or wall defect in HDPE chemical containers
Flash and overhang on bottle neck causing cap seating failure
Short-fill — incorrect quantity of hazardous material in sealed container
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Plastic Packaging Manufacturers
Your Customers Are Pharma and FMCG Brands. Their Audit Is Your Audit.
Bottle and cap makers who supply regulated industries carry their customers' quality expectations. We help you meet them — without slowing production.
Common Production Problems
Short moulding — insufficient material in critical zones
Wall thickness variation — collapse under customer's capping pressure
Black spots, burn marks, material inclusions from contaminated granulate
Seal surface damage preventing effective induction sealing downstream
Cap liner missing, misaligned, or double-lined at assembly speed
📄Case Study: FMCG Bottle Maker — BIS on 4 Lines in 6 Days
2.4M HDPE bottles/month · ₹28L customer returns eliminated · Full AQL replacement
Read Case Study →
📌 Replace placeholders with actual defect images from production. Defect images are the single highest-converting visual element on this page.
The Physics of Inspection
Why Vision Inspection is Hard — And Why We've Solved It
Anyone can list industries. What separates working inspection systems from failed ones is understanding these specific challenges — and designing around them.
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Faint vs Prominent Defect Detection
A 5mm black spot stops a line. A 0.3mm surface haze causes cap seal failure at temperature. Most systems catch one or the other. Optomech uses adaptive thresholding — sensitivity set per defect class, not a single global threshold.
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Transparent & Translucent Containers
PET and glass create reflections that fake defects or hide real ones. Coaxial and low-angle lighting combinations separate actual wall defects from optical artefacts. Most single-light setups fail here.
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Reflective and Curved Surfaces
Metallic caps and curved bottle shoulders cause light scatter overwhelming single-camera systems. Multi-camera architectures at calibrated angles eliminate dead zones that hide defects from single viewpoints.
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High-Speed Line Instability
At 400+ CPM, bottles arrive with position variation, tilt, and speed jitter. Our systems use encoder-triggered image capture — not time-triggered — ensuring every unit is imaged at the correct position regardless of speed variation.
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Colour & Gloss Variation in Normal Production
AI models trained on a customer's actual parts — not generic library data — learn what normal variation looks like. This is what reduces false rejects by 30–60% vs fixed-threshold systems that reject good parts as defective.
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Changeover Complexity on Multi-SKU Lines
A line running 40+ SKUs needs recipe-driven changeover: one touchscreen selection loads correct reference images, tolerances, and rejection logic for that product. No engineering intervention required between products.
Custom Applications
Your Application Doesn't Fit One Category?
Neither do most real production problems.
Inspection challenges in packaging rarely map cleanly to a single industry. A cosmetics manufacturer may run pharma-grade sealing. A food company may use industrial-grade caps. A bottle maker may supply five sectors from the same line.
Optomech engineers work application-first: describe your product, your defects, and your line speed — we design the camera architecture, lighting, and algorithm to match. Not the other way around.
Share the following and we'll have a technical proposal within 5 working days:
Product type (bottle, cap, label, canister, container)
Material (PET, HDPE, glass, PP, aluminium)
Line speed (CPM / BPH)
Defect types you need to detect
Defect images or samples if available
Current inspection method and its failure mode
Send Your Defect Images
Our application engineers review defect images and propose a detection approach — camera count, lighting setup, and algorithm — typically within 48 hours of a technical discussion.
Answers optimised for clarity — and structured so search engines and AI assistants can find the right answer for your query.
The BIS detects short moulding, thin walls, flashes, ovality, choked necks, black spots and burn marks, holes, pinholes, material inclusions, seal surface damage, shoulder defects, and bottom defects — across HDPE, PET, and glass bottles at speeds of 200–400+ CPM (up to 10,000 BPH).
The ISIVS (Induction Seal Integrity Verification System) uses thermal imaging — not visible light — to detect the heat signature of the induction seal zone on every bottle immediately after the sealing tunnel. It detects under-heating (incomplete adhesion — invisible to visual inspection), over-heating (foil discolouration and brittleness), cut liner, no liner, moon cut, and loose cap. Detection is 100%, non-destructive, and at line speed up to 120 bottles per minute.
Optomech trains AI reference libraries on the customer's actual production samples — including normal variation in colour, surface texture, and gloss. This means the system learns what a good part looks like on that specific line, not from a generic library. This approach reduces false rejections by 30–60% compared to fixed-threshold systems that treat all variation as a potential defect.
AQL (Acceptance Quality Level) sampling inspects a statistical sample — typically 0.9–1.5% of production output. At 10,000 bottles per hour, a 30-minute sampling window leaves 4,000–5,000 bottles completely uninspected. A defect rate of even 0.1% within that uninspected window means 4–5 defective units reaching the customer per batch. Optomech's inline systems inspect every unit at full production speed, eliminating the statistical blind spot entirely.
Discuss Your Application
Share your line speed, product type, and defect images. We'll propose cameras, lighting, and integration — typically within 5 working days.