Reel Inspection System For Tetra Pak

Reel Inspection System for Tetra Pak

Tetra Pak, a leader in food processing and packaging solutions, is dedicated to delivering safe, high-quality packaging to customers in over 160 countries.

Faster Inspections

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Defect Detection Accuracy

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Reduction in Operational Costs

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About Tetra Pak

Tetra Pak, a leader in food processing and packaging solutions, is dedicated to delivering safe, high-quality packaging to customers in over 160 countries. To maintain their reputation for excellence and keep up with growing production demands, Tetra Pak constantly seeks ways to improve operational efficiency and product quality. One critical aspect of their operations is the reel inspection process, which ensures packaging materials meet strict quality standards.

To address inefficiencies in their manual inspection process, Tetra Pak collaborated with The Disrupt Labs to develop an advanced Reel Inspection System. This system automates quality checks for packaging reels, using high-precision technology to detect defects, extract essential data, and provide real-time insights. The solution not only improved inspection accuracy but also reduced operational costs and inspection times, ensuring that Tetra Pak could continue delivering exceptional products while optimizing its production processes.

The Challenge

In the packaging industry, maintaining consistent quality and minimizing downtime are important for operational efficiency. In their manual reel inspection process, Tetra Pak faced several significant challenges that affected efficiency and quality:

01.

Inconsistent Results

The process often led to variations in inspection quality, with some defects being overlooked.

02.

Time-Consuming Process

Inspections took longer than needed, causing delays in production schedules.

03.

Increased Costs

The process required more resources and effort, leading to higher operational expenses.

04.

Errors in Detection

Defects and data were not always identified accurately, compromising the overall quality of the reels.

“The AI-based PPE Monitoring System from The Disrupt Labs has transformed our approach to workplace safety. Automating PPE monitoring has minimized human error, brought compliance levels to over 95%, and saved us countless hours previously spent on manual tracking. The system’s intuitive dashboard and automated reporting allow our management team to make informed, data-driven decisions, significantly boosting both safety and operational efficiency. It has truly set a new benchmark for safety at our facility.”

M/S Axens

Representative

The Solution

To address the challenges, The Disrupt Labs developed a fully automated Reel Inspection System tailored to Tetra Pak’s needs.

AI-Driven Defect Detection

Machine-learning models ensured precise detection of reel defects and real-time extraction of key data such as dimensions, quality grades, and defect types.

Seamless Workflow Integration

The system was designed to integrate smoothly into Tetra Pak’s existing production processes, ensuring uninterrupted operations.

User-Friendly Dashboard

A simplified interface displaying reel defect maps, inspection statistics, and real-time system status, making it easy for operators to monitor performance.

Optimized Imaging Hardware

High-resolution cameras and enhanced lighting delivered clear reel images, integrating smoothly with the existing setup and eliminating the need for costly replacements.

The Outcome

The Reel Inspection System delivered exceptional results for Tetra Pak:

Reduced Inspection Time

The system reduced reel inspection time by 70%, enabling faster production cycles and better time management.

Cost Savings

Operational costs were reduced by 30% by minimizing reliance on workers and improving efficiency.

Enhanced Defect Detection

The system achieved over 95% accuracy in identifying reel defects, eliminating errors caused by manual inspections.

Scalable Design

The modular system allowed easy scaling to handle increased production volumes, making it adaptable to future needs.

Conclusion

The Reel Inspection System has revolutionized Tetra Pak’s quality control process, automating reel inspections to achieve consistent, high-quality results. By reducing inspection time, cutting costs, and enhancing defect detection accuracy, the system has significantly improved operational efficiency. This case study demonstrates how automation and innovative technologies can transform quality control in the packaging industry, reinforcing Tetra Pak’s commitment to excellence and innovation.