We built computer vision quality checks for high-speed bottling and packaging lines, plus AI that routes defective batches and plans truck loading around routes and traffic.
Industry: Manufacturing & EnergyService: AI & Automation
Overview
Client
PepsiCo
Global food and beverage company
Engagement snapshot
The challenge
Bottling and packaging lines ran too fast for people to spot micro-defects in packaging, labels and fill levels reliably.
Calibration problems were found late, and delivery trucks were not always loaded in the most efficient order for their routes.
Small flaws passed at line speed.
Machine drift was noticed after defects built up.
Truck loading did not follow route order.
The solution
Quantised vision transformers on local hardware check packaging, labels and fill levels instantly.
An AI operations agent routes defective batches and alerts floor managers to calibration issues.
An AI logistics module orders truck loading around route efficiency and live traffic.
Key features
Vision models on local hardware check packaging, labels and fill levels at line speed.
Business impact
Defect rates near zero
An AI agent moves defective batches aside and alerts managers to calibration issues.
Business impact
Faster fixes on the line
AI orders truck loading by route efficiency and real-time traffic.
Business impact
Lower fleet fuel use
Before and after
Before
Spot checks
People sampled packages at line speed.
After
Every package checked
Vision models inspect each unit.
Before
Found late
Drift was noticed after defects built up.
After
Flagged early
Managers are alerted to calibration issues.
Before
Fixed order
Loading did not follow route order.
After
AI-planned
Sequences follow route efficiency and traffic.
Results
Near-Zero Defect Rate
Defect rates on the bottling lines came down to near zero.
Before: Spot ChecksAfter: Every Unit Checked
Lower Fuel Consumption
AI-planned loading sequences cut fleet fuel consumption.
Before: Fixed LoadingAfter: AI-Planned Loading
Faster Daily Deliveries
Daily delivery times got faster.
Before: Static PlansAfter: Route-Aware Plans
Testimonial
“Integrating computer vision on our bottling lines brought defect rates down to near zero. Furthermore, the AI-optimized loading sequences have cut our fleet fuel consumption and accelerated daily delivery times.”
Elizabeth XuDirector of Global Operations, PepsiCoKey results
Trust and control
Floor managers decide how to fix calibration issues.
HUMAN IN CONTROLVideo is processed on hardware at the line.
ON-SITEEvery defect and routing decision is recorded.
TRACEABLEInspection thresholds can be adjusted per product.
ADAPTABLEFaster delivery
Building on tested components let the team focus on each line's defect types and speeds.
Tested components ran quantised models on local hardware.
A reusable labelling workflow trained models on real defects.
Ready-made alerts reach floor managers quickly.
Tested routing logic planned loading sequences.
We built computer vision quality assurance for high-speed bottling and packaging lines. Quantised vision transformer models on local hardware detect micro-defects in packaging, labelling and fill levels instantly, and an AI operations agent routes defective batches and alerts floor managers to calibration issues as they appear.
Instead of people spot-checking packages at line speed, vision models inspect every unit as it passes. Integrating computer vision on the bottling lines brought defect rates down to near zero, and floor managers now hear about calibration problems early instead of after defective stock has built up.
An AI logistics module plans the order in which delivery trucks are loaded, based on route efficiency and real-time traffic data. The optimised loading sequences cut fleet fuel consumption and made daily delivery times faster, so the same AI work improves both production quality and distribution.
If defects slip past your packaging lines, we can build computer vision that catches them instantly.