Sealing Surface Specialist · AI-Powered Vision

BIS-SC — Top Sealing Surface Inspection System

The sealing surface is the most critical millimetre of every bottle. A single flash, cut, or trace of product contamination on the lip breaks the hermetic seal — causing leaks, customer returns, and regulatory risk. The Optomech BIS-SC inspects 100% of bottles at up to 7,000 per hour, catching every defect before the cap goes on.

⚡ 7,000 bph 📷 Single Camera · Coaxial Light 🤖 AI-Powered Detection ✅ 21 CFR Part 11 🏭 Moulding + Filling Lines
7,000
Bottles / Hour
Max Throughput
0.2 mm
Detection Accuracy
Sealing Surface
100%
Bottles Inspected
Zero Sampling
2-in-1
Moulding Defects
+ Filling Contamination
Close-up of bottle top sealing surface showing the annular lip that contacts the cap — inspected by BIS-SC
The top sealing surface — the annular ring that contacts the cap or induction seal — is the most defect-critical zone on every bottle. A single imperfection here can compromise the entire product.
Why Sealing Surface Inspection

A defect you cannot see causes a failure you cannot afford

The top sealing surface (bottle lip) is just a few millimetres wide — yet it is the sole contact point between the bottle and its cap or induction seal. Flash, short moulding, cuts, material inclusions, or even traces of the filled product on this surface will prevent a hermetic seal, leading to leakage, contamination, and spoilage.

  • 🔬

    Moulding defects go undetected until the cap fails

    Flash, short mould, cuts and material inclusions from the moulding process create micro-gaps on the sealing surface that no visual manual check can reliably catch at production speed.

  • 💧

    Filling spillage destroys the seal you thought was perfect

    During filling, even a correctly moulded bottle can have product, powder, or liquid deposited on its lip — contaminating the sealing surface before the cap is applied. This is invisible in a standard visual check but causes leaks in transit.

  • ⚠️

    Zero-tolerance industries demand 100% verification

    Pharmaceutical, food, nutraceutical, and agrochemical products require hermetically sealed containers to meet regulatory requirements, maintain product integrity, and protect consumer safety.

  • 🚫

    Manual inspection is too slow and too inconsistent

    At modern line speeds of 5,000–7,000 bottles per hour, manual inspection of each sealing surface is impossible. Inspectors fatigue within minutes and miss the very defects that cause the most costly customer complaints.

Who Uses BIS-SC

One machine — two critical use cases

The BIS-SC is designed to work at the bottle manufacturer's plant and on the brand owner's filling line — delivering complete sealing surface quality control across the entire supply chain.

🏭

Bottle Manufacturers & Converters

Place the BIS-SC at the output of your blow moulding or injection moulding line to catch sealing surface defects before bottles leave your plant. Send only conforming bottles to your customers — and back your quality with data.

  • Detects flash, short mould, cuts and material inclusions from the moulding process
  • Identifies which mould cavity is producing defects — enabling targeted corrective action
  • Generates inspection reports and traceability data for customer quality requirements
  • Eliminates customer complaints and return shipments from sealing failures
🧴

FMCG, Pharma & Food Filling Lines

Position the BIS-SC on your filling line — after the filling station and before the capping machine. It catches both pre-existing moulding defects and fresh contamination from the filling process.

  • Detects product on lip, powder on lip and liquid contamination from filling nozzles
  • Catches moulding defects that passed through incoming quality control
  • Prevents under-sealed caps, induction seal failures and leaking containers
  • Suitable for pharma, food, shampoo, agrochemical, nutraceutical and oil products
Optomech BIS-SC sealing surface inspection machine — single camera overhead inspection unit with control console
Hardware Overview

Precision optics focussed entirely on the sealing surface

The BIS-SC uses a single high-resolution industrial camera with specialised coaxial ring illumination aimed directly down at the bottle lip — delivering a perfect, shadow-free top-down image of the sealing surface on every bottle that passes beneath it.

  • ✔ Single high-resolution industrial camera with precision machine vision lens — dedicated to the sealing surface zone
  • ✔ Coaxial ring LED illumination — custom lighting that eliminates shadows and maximises contrast on the narrow sealing lip
  • ✔ Overhead inspection head mounted on an adjustable column — no contact with the bottle, works with all neck diameters
  • ✔ Inline conveyor integration — bottles pass through on their existing production conveyor, no re-routing required
  • ✔ 21" industrial touchscreen HMI — real-time inspection images, defect counts and statistics on a single screen
  • ✔ Pneumatic rejection system — defective bottles are automatically ejected before reaching the capping machine
  • ✔ Compact footprint — machine dimensions 1870 mm (H) × 604 mm (L) × 355 mm (W) — integrates into tight filling line layouts
  • ✔ Handles diverse bottle formats — up to 230 mm height, up to 110 mm diameter, minimum 50 mm gap between bottles
Defect Detection

Every sealing surface defect — moulding or filling. Nothing passes.

The BIS-SC's AI-powered software analyses each top-down image of the sealing surface against a trained reference model. Any anomaly — whether a manufacturing defect or filling-line contamination — is flagged and the bottle is rejected automatically.

Flash defect on bottle sealing surface — extra material protruding from the sealing lip, detected by BIS-SC
Moulding
Flash / Extra Material
Short moulding defect on bottle sealing surface — under-filled neck finish detected by BIS-SC
Moulding
Short Moulding
Cut or nick defect on bottle sealing surface — sealing ring damage detected by BIS-SC
Moulding
Cuts & Nicks
Powder contamination on bottle sealing surface — product contamination on lip detected by BIS-SC filling line inspection
Filling
Powder on Lip
Defect Source Defects Detected on Sealing Surface
🏭 Moulding Defects
Flash & Extra Material Short Moulding (Under-fill) Cuts & Nicks Black Spots Material Inclusions Diameter Variation Ovality / Deformation
🧴 Filling Contamination
Product on Lip Powder on Lip Liquid Residue on Sealing Surface Foreign Particle Contamination

Note: Blue-tagged defects are detected when the BIS-SC is deployed on filling lines. All defects above are detected when deployed at the moulding plant output.

Key Capabilities

Built for demanding production environments

Everything in the BIS-SC is optimised for one purpose — ensuring every bottle that reaches the capping machine has a clean, defect-free sealing surface.

🤖

Optomech AI Inspection Engine

Advanced AI-based software analyses the complete sealing surface image in real time, distinguishing true defects from normal variation — minimising false rejects while catching every genuine fault.

💡

Coaxial Ring Illumination

Purpose-built coaxial LED ring lighting eliminates shadows across the narrow sealing surface, creating a uniform, high-contrast image that reveals even sub-millimetre defects like hairline cuts or trace contamination.

📱

Live Touchscreen Dashboard

A large monitor displays the sealing surface image of every bottle in real time as it passes through inspection — with defect annotations, rejection counts, and trend statistics always on screen.

🎯

Operator-Tunable Tolerances

Each defect parameter has an adjustable tolerance limit, allowing quality teams to fine-tune sensitivity per product recipe. Accept or reject thresholds can be set separately for each defect type.

💾

Recipe Library & Quick Changeover

Store inspection settings for every bottle SKU in the recipe database. Switching between products requires selecting the saved recipe on the touchscreen — changeover takes seconds, not hours.

📊

Complete Data Traceability

All inspection data, defect images, and batch statistics are stored in a database and can be retrieved at any time. Periodic reports are generated at user-defined frequencies — hourly, shift-wise, daily, or weekly.

🔐

3-Level Access Control

Separate password-protected access for User, Supervisor, and Administrator roles — ensuring that only authorised personnel can modify inspection parameters, recipes, or system settings.

🔧

Remote Support & Diagnostics

Optomech engineers can access the BIS-SC remotely for diagnostics, recipe optimisation, software updates, and troubleshooting — minimising downtime without waiting for an on-site visit.

⚙️

Easy Line Integration

The BIS-SC mounts directly over the existing production conveyor. No special bottle transport or line redesign is required in most installations — setup is fast and disruption to production is minimal.

Industries Served

Any industry that fills and caps a bottle

The BIS-SC is designed for any product that is filled into a bottle, capped, and sealed. If the sealing surface is compromised, the product is at risk — regardless of the sector.

💊

Pharmaceutical

Tablets, capsules, syrups, suspensions, ophthalmic drops — regulatory compliance and patient safety demand a perfect seal every time.

🧴

FMCG & Personal Care

Shampoo, conditioner, lotion, liquid soap — sealing failures cause in-transit leaks and shelf damage that result in consumer returns.

🌿

Nutraceuticals

Protein powders, vitamins, health supplements — powder products are especially prone to contaminating the sealing surface during filling.

🌾

Agrochemicals

Pesticides, herbicides, fertiliser concentrates — a failed seal on a hazardous chemical container is a safety and liability risk.

🍶

Food & Edible Oils

Oils, sauces, vinegar, condiments — seal integrity is critical for food safety compliance and preventing spoilage in the supply chain.

🧪

Specialty Chemicals

Industrial lubricants, cleaning agents, adhesives — chemical product integrity and safe packaging compliance require verified sealing.

🏺

Bottle Manufacturers

HDPE, PET, PP blow moulders and converters — supply defect-free bottles with full inspection data to differentiate in a competitive market.

🫙

Cosmetics & Beauty

Serums, toners, face washes — luxury product packaging demands zero visible defects and airtight sealing to protect formulations.

Software & Compliance

Smart software. Full data traceability. 21 CFR Part 11 compliant.

21 CFR Part 11 GMP Ready Excel Export Remote Access 3-Level Access
  • ✔ Real-time sealing surface images displayed on large monitor as every bottle passes through inspection
  • ✔ Defect frequency statistics and rejection counts updated in real time — shift-by-shift quality monitoring
  • ✔ Easy-to-define tolerances — operators decide exactly which bottles are accepted or rejected per defect type
  • ✔ Quick product changeover — select a saved recipe from the touchscreen to switch bottle formats in seconds
  • ✔ All inspection data stored in database — complete traceability, retrievable at any time for QA review or audits
  • ✔ Periodic reports generated at user-defined frequency — hourly, shift, daily or weekly — in Excel format
  • ✔ 3-level access control — User / Supervisor / Administrator via separate passwords for security compliance
  • ✔ Automatic rejection trigger — pneumatic ejector activated instantly, no operator intervention needed
Optomech BIS-SC software screen — showing sealing surface inspection image and defect detection overlays
Technical Specifications

BIS-SC Technical Specifications

Designed and manufactured at Optomech's facility in Hyderabad, India. Specifications are subject to modification in the interest of product development.

Parameter Specification
Model Optomech BIS-SC — Top Sealing Surface Inspection System
Application 100% inspection of bottle top sealing surface (lip) — moulding lines and filling lines
Inspection Speed Up to 7,000 bottles per hour
Bottle Height (max) 230 mm
Bottle Diameter (max) 110 mm
Min. Gap Between Bottles 50 mm
Detection Accuracy 0.2 mm (for bottle height up to 50 mm)
Number of Cameras 1 high-resolution industrial camera with machine vision lens
Illumination Specialised coaxial ring LED illumination — optimised for sealing surface imaging
Inspection Zone Top sealing surface (bottle lip / neck finish)
Defects Detected Flash, short moulding, cuts, black spots, material inclusions, diameter variation, product on lip, powder on lip
HMI Large industrial monitor — real-time inspection images and statistics
Rejection System Pneumatic automatic rejection
Access Control 3-level: User / Supervisor / Administrator (separate passwords)
Software Compliance 21 CFR Part 11 compliant
Data Storage Full inspection database — all data and images retrievable at any time
Reporting Periodic reports at user-defined frequency (hourly / shift / daily / weekly)
Machine Dimensions Height: 1870 mm · Length: 604 mm · Width: 355 mm
Manufactured by Optomech Engineers Pvt. Ltd., Hyderabad, India
Product Video

See the BIS-SC Sealing Surface Inspection in Action

Watch the Optomech BIS-SC inspecting bottle top sealing surfaces live — real machine, real bottles, real production conditions.

BIS-SC — Bottle Top Sealing Surface Inspection System · Live Machine Demo
Frequently Asked Questions

Common questions about BIS-SC sealing surface inspection

The Optomech BIS-SC is a specialised machine vision system that inspects only the top sealing surface (lip) of bottles — the annular ring surface that contacts the cap or seal. It uses a single high-resolution camera with coaxial lighting to capture a perfect top-down view of every bottle's sealing surface at up to 7,000 bottles per hour, detecting manufacturing defects and filling-line contamination with 0.2 mm accuracy.
The BIS-SC detects: Flash and extra material on the sealing lip, Short moulding (under-fill of the sealing surface), Cuts and nicks on the sealing ring, Black spots and dark inclusions, Material contamination and foreign inclusions, Powder on lip (from powder-filling operations), Product on lip (from liquid filling spillage or overfill), Diameter variations of the sealing ring, and Ovality or deformation of the neck finish.
Both. Bottle manufacturers use the BIS-SC at the output of their moulding line to catch manufacturing defects before bottles are dispatched. FMCG, pharmaceutical, food, agrochemical, nutraceutical and oil companies use the BIS-SC on their filling line — placed after the filling station and before the capping machine — to detect both moulding defects and filling-line contamination such as product or powder on the sealing lip.
The top sealing surface is the only point of contact between the bottle and the cap or induction seal. Any defect — even a microscopic flash, a cut, or a trace of product spillage on the lip — breaks the hermetic seal, allowing air ingress, leakage, contamination, or loss of tamper evidence. A single defective seal in a pharmaceutical or food bottle can trigger customer complaints, product recalls, regulatory action, and serious brand damage.
The BIS-SC camera captures a top-down coaxial image of the sealing surface under specialised ring illumination. The Optomech AI software compares the image against a trained reference model of a clean sealing surface. Any foreign material — powder, liquid product, residue — creates a contrast anomaly on the clean annular ring and is flagged for rejection. This works regardless of whether the contamination comes from the filling nozzle, conveyor splashing, or overfilling.
Yes. The BIS-SC software is 21 CFR Part 11 compliant with three-level access control (User, Supervisor, Administrator), a full audit trail, operator-defined tolerance limits per product recipe, and complete data storage for traceability. All inspection data and captured images are stored in a database and can be retrieved at any time.
The BIS-SC handles bottles up to 230 mm in height and 110 mm in diameter. It works with HDPE, PET, PP and other plastic bottles across a wide range of packaging formats — from personal care and pharmaceutical bottles to food jars and agrochemical containers. The minimum gap between bottles on the conveyor should be at least 50 mm.
The BIS-SC is a single-zone specialist — it inspects only the top sealing surface, making it compact, cost-effective, and easy to integrate on any filling or moulding line. A full BIS-XL or BIS STD+ system inspects the sealing surface plus sidewall, base, and inside the bottle across multiple camera zones. For filling lines where the primary risk is sealing surface contamination from filling, or for bottle converters focused on neck finish quality, the BIS-SC delivers exactly the right inspection scope at the right price point.

Seal every bottle with confidence

Talk to an Optomech application engineer about deploying the BIS-SC on your moulding line or filling line. We'll assess your bottle formats, line speed, and defect requirements — and recommend the right inspection solution.

Request a Demo → ✉ sales@optomech.in

Optomech Engineers Pvt. Ltd. · 3A Type II, IE Kukatpally, Hyderabad 500 072 · +91 40 23078371