KHS GmbH has announced the integration of artificial intelligence into its Innocheck TSI closure inspection unit in response to the growing complexity of inspecting tethered caps. These closures have been mandatory on all non-returnable PET bottles in the European Union since 2024, creating new technical challenges for beverage producers.
According to KHS, the number of cap and bottle variants has increased significantly under the new regulations, placing higher demands on inspection technology. “Tethered caps were rarely used before the EU directive came into force. Conventional systems thus frequently reach the limits of their capacity where cap inspection is concerned,” said Nikita Wall from KHS’ Labeling and Inspection Technology Product Support team.
The new AI-based fault detection module leverages patent-pending algorithms to improve accuracy and efficiency in cap inspection. Cameras capture high-resolution images of closures, which are then analyzed in real time by AI models using deep learning. This enables the system to identify a wide range of defect types, including new or evolving flaws.
KHS reports that the AI-supported system has undergone intensive field testing, with results meeting the high quality assurance standards expected by customers. “Our customers make extremely high demands of quality assurance. In intensive field tests, our AI-based fault detector has proved that it fully meets these requirements,” Wall added.
The AI module can be retrofitted to existing Innocheck TSI units, as well as integrated into new systems. KHS is also evaluating the use of similar AI tools in other inspection technologies, depending on the complexity of requirements and potential benefits.