Application of Atonm MDSC-2100L Single/Double Sheet Detector in Bottle Cap Gasket Detection

1. Project Background

In the field of food and pharmaceutical packaging, the sealing quality of bottle caps is directly related to the product's shelf life. A high-end bottle cap manufacturing enterprise faced a problem during the aluminum foil gasket insertion process: due to the thin and light nature of the gaskets, stacking (double gaskets) often occurred, resulting in defective products with double gaskets. If these defective products flow to downstream processes, they will pose quality risks such as difficult opening and leakage.

Previously, the enterprise employed 2 quality inspectors for manual screening, incurring an annual labor cost of 80,000 yuan. Additionally, the material loss caused by rework processes amounted to 72,000 yuan per year. Even with manual inspection, a 0.8% missed detection rate still remained, leaving potential quality hazards. Therefore, an automated detection solution was urgently needed.

2. Working Condition Analysis

The detection target and production line parameters of this project put clear requirements on the equipment:

Material Characteristics: The aluminum foil gasket has an outer diameter of 22mm and a total thickness of 0.05mm, with the metal layer being only 0.02mm. This belongs to an ultra-thin detection scenario, where conventional sensors are prone to misjudgment.

Production Rhythm Adaptation: The gasket insertion speed is 100 pieces per minute. The response speed of the detection equipment must match the production line rhythm to avoid missed detections or incorrect rejection due to delays.

Limited Installation Space: The existing gasket insertion equipment has a compact structure, so the sensor must be small in size and flexible for installation.

3. Solution: MDSC-2100L Single-Probe Single/Double Sheet Detection Sensor

To address the above working condition challenges, the technical team conducted multiple rounds of solution demonstration and finally selected the Atonm single-probe metal double-sheet detector MDSC-2100L as the core solution. Its technical characteristics highly align with the project requirements:

3.1 Equipment Technical Advantages

The MDSC-2100L metal single/double sheet detector adopts customized high-sensitivity electromagnetic induction technology, which is suitable for ultra-thin metal material detection. According to product parameters:

Its detection thickness range covers 0.01-0.1mm, which can meet the detection requirement for the 0.02mm metal layer in this project.

Its response speed reaches 1200pcs/min, which is 12 times the actual production line speed (100 pieces per minute), capable of meeting high-speed detection needs.

The high-sensitivity small-probe sensor can be installed and used even on equipment with a compact internal structure.

3.2 Product Installation Details

Sensor Selection and Installation: The M12 single-probe SE-2100LC-F6.0 (12mm in diameter × 35mm in length) is selected, which is compatible with the compact space of the gasket insertion table.

The probe is installed in linkage with the cylinder through a customized bracket: After the gasket is inserted into the bottle cap, the gasket insertion table rotates to the detection position, and the cylinder pushes the probe to contact the bottle cap to quickly complete single/double sheet detection.

After detection, the cylinder drives the probe to reset, ensuring that the continuous rotation rhythm of the gasket insertion table is not affected.

Product Installation Details

Sensor Selection and Installation: The M12 single-probe SE-2100LC-F6.0 (12mm in diameter × 35mm in length) is selected, which is compatible with the compact space of the gasket insertion table.

The probe is installed in linkage with the cylinder through a customized bracket: After the gasket is inserted into the bottle cap, the gasket insertion table rotates to the detection position, and the cylinder pushes the probe to contact the bottle cap to quickly complete single/double sheet detection.

After detection, the cylinder drives the probe to reset, ensuring that the continuous rotation rhythm of the gasket insertion table is not affected.

4. Customer Benefits

Three months after the MDSC-2100L metal single/double sheet detector was put into operation, the production line data showed significant improvements, achieving simultaneous enhancement of quality control and production efficiency:

Quality Control Improvement: Defective products with double gaskets inserted into caps are effectively controlled, with a missed detection rate of 0. This significantly reduces sealing quality complaints caused by gasket stacking, and the number of sealing complaints from downstream customers has decreased by 92% compared with before.

Production Efficiency Enhancement: The average daily effective production capacity has increased by approximately 1,200 units. Based on 300 production days a year, the annual new production capacity reaches 360,000 units.

Good Equipment Stability: The production change and commissioning process is convenient and efficient, which improves the flexibility of producing multi-specification bottle caps.

5. Summary

In this case, the Atonm MDSC-2100L metal single/double sheet detector solved the problem of stacking detection for 0.02mm ultra-thin aluminum foil gaskets through customized application, providing a replicable solution for refined quality control in the packaging industry. Its core value lies in two aspects: on the one hand, it realizes effective detection through high-sensitivity detection technology; on the other hand, it meets the adaptation requirements of the production line with its compact design and fast response.

For industries with high requirements for sealing quality such as food and pharmaceuticals, the MDSC-2100L metal single/double sheet detector has strong scenario adaptability. It can not only meet the detection needs of ultra-thin and small gaskets but also adapt to the rhythm requirements of medium and high-speed production lines, providing technical support for enterprises to balance cost reduction, efficiency improvement and quality upgrading.