Long-range Mark Sensor | Color Sensor Application on Bottle Cap Production Line

Project Background：

The customer is a packaging company producing various bottle caps. Ensuring each cap has the correct gasket is critical. The challenge is to efficiently and accurately identify different gasket types to prevent wrong products entering the next process.

Solution：

Atonm engineers discussed requirements and working conditions and found:

Gasket types：

1. Silver gasket (correct)

2. Gasket with red logo (wrong)

3. No gasket (wrong)

4. Cap diameter: 38mm

5. Throughput: 30-40 caps per minute

After evaluation, Atonm selected the long range white spot mark sensor CL4 to solve gasket classification and provided on site trial service.

Implementation：

The mark sensor CL4 was installed above the conveyor to inspect each cap. The sensor analyzes gasket status in real time:

- When a silver gasket is detected the system allows the cap to pass.

- For caps with a red logo gasket or no gasket, the sensor triggers a blow off to divert incorrect products into a collection bag.

CL4 mark sensor is a long range mark sensor with detection distance up to 500mm, using white LED and custom photodetector. It captures subtle color differences and is less affected by tilt or distance changes.

Customer Benefits：

After introduction the CL4 mark sensor delivered stable detection with zero false positives in trials. The customer achieved real time quality control and improved efficiency and product quality, and plans to expand the solution to other lines.

Contact Atonm for similar challenges and professional solutions to make your line more efficient and safer.