Dynamic Checkweighers are used to detect variations in product weight and identify packages with missing instructions. They assist in finding and removing faulty products prior they can reach to end consumers.
This scenario is of crucial significance when it comes to pharma products, as missing instructions for precise utilization can lead to a product recall damaging your business brand in front of your clients and even impact their end consumers.
Here are key reasons why you require checkweigher solutions in pharma industry
#1. Improve Process Safety and Tracking Options
Checkweighers in the Pharma industry can be equipped with additional tools, which adds further tracking preferences to comply with quality assurance regulations. This does not merely comprise completeness verification; however, it even removes packages, which may otherwise negatively impact the production procedure.
The system identifies these challenges and gets rid of problematic products, and can even be programmed to sort the unwanted products into reject bins with respect to the diverse issues.
#2. Ensure Process Validation and Compliance
We advise all our clients to keep an audit trail. However, in the pharma industry, such things are not just a recommendation – they are a necessity. Our Pharmaceutical Checkweighers assist our clients in attaining compliance with needed regulations.
#3. Increase Profits and Revenue
While Checkweigher Solutions are most of the times associated with validation and compliance, they even reduce waste, help with tolerances, and assist in producing precise products. They offer long term contribution to better productivity and ultimately profits with unfailing ROI.
#4. Avoid Regulatory Fines
As we mentioned above, checkweigher solutions make sure compliance with governmental regulations and industry benchmarks. With comprehensive weight inspections and precision, they help you to avoid any types of fines. They assist in delivering accurate processes that are required in today’s demanding market, especially in the pharma industry.
#5. Enable Active Checkweigher Feedbacks
Checkweigher solutions can help in keeping an eye on filler performance to put off unnecessary over and under-fills by feedbacks. Checkweighers can be blended with the filler control or networked to present factory floor automation solutions for flawless feedback control.
#6. Blended Metrics Steers Process Enhancements
Checkweighers offer real-time monitoring of production processes which include yield statistics, all of which can be utilized for process enhancements and boosting operating efficiencies.
#7. Eradicate Manual Efforts
The use of manual scales to identify and check products takes more time, efforts and involves inaccuracies in operations. However, by switching to dynamic Checkweighing solutions you can shun errors and reduce labor costs by eradicating manual efforts and bringing in automation.
#8. Reduction in False Rejects and Rework
Processes that enable precise and maintained checkweigher systems offer fewer rejected products. Tight tolerances deliver enhanced process quality and also reduce rework on products manufactured. Reduction in false rejects offer better checkweigher accuracies and the probable zone of production uncertainties can be controlled.
#9. Finally, Reduce the Risk of Product Recalls
For mitigating the risk of product recalls because of inaccurately packaged specific pharmaceutical products, manufacturers have the choice of enabling a Checkweighing solution that is built explicitly for the specific application in the pharma business.
Moving Forward: By Making the Correct Choice
The precise checkweigher is equipped with the functionalities required to ease regulatory compliance, overcome production issues and make sure it meets the high benchmarks set by industry leaders.
However, even an ideal checkweigher solution takes work to implement, which is why choosing a reliable and experienced technology provider can lend a hand to make things easy.
A right technology partner will assist you at every stage of the way, providing guidance on everything from the placement of the checkweigher solution to its implementation and maintenance.
Shubham Automation has decades of experience in developing diverse kinds of Checkweigher Solutions. Our Checkweigher solutions for the Pharmaceutical industry make sure that the pharma products of our clients are up to the yardstick of weight and excellence by efficiently following the defined procedures. To know more about our Quality Assurance Solutions for diverse industries and usages, connect with us today!
If you are in the manufacturing or packaging business, enabling the packaging lines is one of the major priorities. But it is not always the game of boosting the process speeds. A significant focus should be on making sure the correctness of the weight.
Getting a start here is no challenging task as a checkweigher can do this job for you. However, let’s explore the overall value of a checkweigher and how to select the precise one.
What is the Significance of a Checkweigher Solution?
When you have a superior checkweigher, you can stay assured that the precise quantity of material gets filled in every package. When there is no additional product giveaway, you can directly enhance your profits and meet the production benchmarks.
A step further, checkweigher Solutions assists you in analyzing the operational procedures and get better in areas where there are challenges.
How to Select a Checkweigher Solution
Essential Factors to Remember when Deciding on a Checkweigher Solution
#1. Choosing the Checkweighing Solution that Suits your Business
Defining your precise operational requirements is vital when deciding on a checkweigher machine. Once you have your manufacturing and packaging objectives in mind, it turns simple to figure out the precise check weighing system that would be entirely applicable for your needs.
Checkweighing Solutions can be bifurcated into two main categories: Static and Dynamic.
- Static Checkweighers: These Checkweighers measure the weight of products that are not in constant motion and are utilized to check the weight of a small number of products. They can be used to make sure the products comply with industry standards.
- Dynamic Checkweighers: These Checkweighers assists in weighing products in some motion automatically and work without any manual inputs. They are equipped with automated removal devices to dispose off-weight items and also offer significant production data for process enhancements. They comply with precise industry regulations and measures.
#2. Item Characteristics Dealt with their Packages
Some Checkweighers are developed mainly for specific packages such as boxes, cases, bags, cans, and cartons. Other products such as tall bottles may also need specific checkweigher solutions.
Regular package categories weighed usually comprise of:
Depending on the overall size and average weight of products, you can consider the precise size of your checkweigher with respect to belt dimensions and the load cell weighing range. Even factors like product height, shape, and footprint affect the correct precision of Checkweigher Solutions.
#3. Environmental Conditions of Workplace
The precision and efficiency of Checkweighing will be impacted by the surrounding environmental conditions, which are required to be checked before deciding on a Checkweigher Solution.
- Check the below conditions before buying a Checkweigher Solution:
- Is your workplace under extreme temperature?
- How is the air current at your workplace?
- Are your workplace units safeguarded from electrical noise?
- Is there moisture across the products to be weighed?
- Will your Checkweigher be exposed to dust, water, noise or redundant signals?
#4. Software & Technical Compatibility
Selecting the precise Checkweighing solution will optimistically impact your productivity and revenue. There are accessible Checkweighers that are blended with software choices and connectivity to make sure the best possible technical compatibilities.
The advanced software facilitates accuracy and swiftness and provides in-depth analysis, which assists in resolving issues across the packaging lines.
#5. Selecting the Right Technology Partner
Shubham Automations has been delivering industry-leading Checkweigher solutions across the globe for over 15 years now. Our teams have designed numerous Checkweigher solutions in diverse industries such as Chemicals, Pharmaceuticals, Packaging, FMCG, Food & Beverages and Fertilizers.
Our systems provide ease in maintenance and offer enhanced uptime while enabling the operator simplicity by touch screen displays. We have even designed customized Checkweigher solutions for different industries.
When you invest in an automatic and dynamic checkweigher solution, keep these characteristics in mind to spot the precise one that fits your business domain.
As a leading provider of Automation, Quality Assurance and Track & Trace Solutions, Shubham Automation assists you to get the best checkweigher systems. At Shubham, we have multiple preferences and options to choose from the series of our Checkweigher systems. The selection can effectively be made based on the exact requirements of the client. To know more about our solutions for diverse industries and usages, connect with us today!
Checkweighers are utilised as an integral part of quality control programs, where manufacturers rest assured that they comply with benchmark regulations and enable products in precise amounts.
On the other hand, consumers can be fully assured that they are using superior quality products that contain all the elements or parts, as mentioned on the packaging.
How Checkweigher Systems Work
A Checkweigher is a system that precisely weighs products as they pass by a production line, then classifies the products by set weight zones, and sorts or reject products as per the classifications.
Checkweighers weigh the products comprehensively right on a production line and offer the complete overview of production data, including production counts, batch monitoring and tracking, total weights, accepted and rejected weights.
Uses of Checkweigher Solutions
They are utilised for numerous applications, which include:
- Checking for under and overweight product packages
- Make sure compliance with net contents
- Check missing components in a package
- Verify product counts by weight
- Check package mixes regards to weight limits
- Eliminates the possibility of product giveaway
- Classifying products into diverse weight zones
- Make sure product compliance
- Weighing prior to and after a procedure to check the performance
- Fulfill reporting benchmarks
- Measure and report efficiency across production lines
Benefits of Checkweigher Solutions
Checkweigher solutions avoid fines and safeguard your business brand with complete weight inspections. One of the significant reasons to use a Checkweigher system is to comply with regulations and industry benchmarks. So, comprehensive weight inspection should be a crucial part of a quality and process control program. And the added advantage of an automated Checkweigher is that information earlier gathered manually can now be automatically collected in minimal time.
For these various reasons, an organisation’s responsibility is to safeguard its brand and protect the end consumers. Product brands are significant assets that require to be handled precisely and protect from negative publicity. Underweight product purchased by consumers can have an off-putting effect on an organisation, leading to brand damage and expensive product recalls.
In the case of an organisation being investigated as an outcome of a consumer complaint, documentation will offer evidence of the precise operation of the Checkweighing set-up program.
Gains from Checkweigher Solutions
#1 Enable Trust and Business Opportunities
To make sure client and end-consumer contentment, manufacturers must deliver accurate product quality by removing the risk of manufacturing under-filled products or products with missing components. Failure in doing so can undesirably lead to loss of trust between the involved retailer, consumer and the manufacturer and can cause a breakdown of relationships along with loss of business opportunities in the longer term.
#2 Safeguard Brand Reputation
The positive product branding offers consumers a consistent assurance of quality and security. Branding plays a vital role in steering customer repeat purchases and so is an essential tool in boosting sales and justifying product costs by retailers and manufacturers.
#3 Cost-effectiveness and Improved Use of Resources
A precise Checkweigher will make sure tighter production tolerances that will create less waste and facilitate more final products to be manufactured from the same inventory. So, Checkweighers should be an in-built part of a manufacturing set-up to make the most of the current resources.
#4 Less Rework and Fewer Rejections
A well-maintained Checkweigher system enable processes to reduce work load and have fewer rejection of products. With tighter tolerances manufacturers can enhance the process quality, trim down the scrapped products and those needing re-work.
With Checkweigher solutions false rejects are reduced as processes become streamlined and highly refined. The in-line Checkweigher further removes probable sampling mistakes and lessens additional labour costs needed for static checking.
#5 Enrichment in Accessibility, Performance, and Quality Levels
Overall Equipment Effectiveness (OEE) is improved by enhancements in accessibility, performance, and quality levels. Comprehensive monitoring of products offers precise process variations, reduction in line capacity and tight production tolerances through Checkweighing. It also trims down over fills and under fills which boosts a higher yield of quality products.
When deciding which Checkweigher solution is precise for a specific product and production line, the manufacturers should initiate to analyze existing processes within their operations. They should specifically consider the weight, shape and size of products with explicit production environment and even check whether the solution meets their brand requirements.
Shubham Automation offers a diverse range of Checkweigher solutions. Our Checkweigher Solutions protects products from accuracy and correctness challenges. Our teams help Pesticides, FMCG, Food & Beverages, and Pharmaceutical manufacturers to eliminate errors, defects, and resolve product challenges so that the consumer has the correct product in his hand.
FMCG product manufacturers provide consumers with a variety of products across the marketplaces. With numerous products to select from diverse sizes, colours, styles, and brands, it is significant for FMCG product manufacturers to track their products’ quality right from source to shelf.
Furthermore, with increasing competition for shelf space, these manufacturers will require being more conscious in controlling inventories and making sure they constantly meet the quality expected by their customers.
Today’s FMCG Marketplace
The packaging processes are transforming the FMCG sector with its capabilities to serve as a marketing vehicle and even enable packaging solutions that can save profit margins. Sustainable packaging is environmentally friendly, cost-efficient, and reduces waste. It also backs packaging with recyclable and postconsumer materials to make sure package quality is quite ready for their retailers across the marketplaces.
FMCG can be a Risky Business
With safety regulations being authorized by government bodies within diverse industries, the FMCG product manufacturing processes also face risks leading to product recalls and issues in meeting industry benchmarks.
By facilitating production benchmarks, regulatory bodies want manufacturers to implement preventative quality controls to reduce hazards, industry challenges and have safe product packaging to eradicate business risks.
Where Vision Inspection Solutions Fits into Your Manufacturing Lines
Comprehensive detection of defective products right in the production procedures is now turning a requisite for the FMCG sector. At Shubham Automation, we can seamlessly integrate a vision inspection solution into your current production lines to assist you in meeting safety, compliance, and correctness of products.
Crucial defects can occur anywhere along the manufacturing and packaging lines; however, with our solutions faulty products can be precisely detected and rejected prior to leaving the manufacturer’s factory floor.
Vision Inspection Solution Sustains Perfection
To remain competitive, FMCG manufacturers are continuously launching new products into their manufacturing lines, and as product variety matures, the risks of packaging mistakes and defects are bound to increase. However, today, packaging quality can be controlled by the use of vision inspection solutions.
By detecting where packaging errors occur on the manufacturing lines, effective vision inspection solutions at crucial control points can detect the erroneous products and assist in removing them from the production lines.
The Competitive Benefits
By partnering with a vision inspection solution provider like Shubham Automation, manufacturers can attain quality control throughout the complete supply chain, safeguarding their brand and profitability. Automated vision inspection systems help FMCG manufacturers always meet needed compliance, provide safe products, and help achieve optimal production.
Automated vision inspection solutions exceed the abilities of manual inspections and help in reducing the overall downtime. With the enablement of connectivity abilities, vision inspection systems deliver the required flexibility and sustainability expected by manufacturers out of their production lines.
Here are the benefits and advantages experienced when using vision inspection solutions:
- Label Inspections
These inspections automatically inspect labels on all products, including bottles, boxes, vials, cans, trays, and tubs. They ensure label matches packaged product contents and branding on products are conveyed as needed, safeguarding manufacturers from possible miss-branding violations.
- Seal Inspections
These inspections put a stop to the risk of content contamination which can occur because of an erroneous tamper-resistant band or faulty seal.
- Integrity Inspections
These inspections check packaging elements to verify that containers have been completely packed to match the precise quality and fit customer usages.
- Printed Code Verification
These verifications check that printed barcode and 2D matrix codes are accurate and adequately readable. It even backs product tracking and monitoring, while product recalls are involved right in the supply chain.
- Check Fill Level
These vision inspections checks and verify that filled containers are correctly filled as per the industry standards, removing the possibilities of product waste or unhappy customers.
Shubham Automation’s automated vision inspection solution PCC ACCURA delivers modern-day technology with higher performance image processing in the FMCG sector across the production and packaging areas.
Shubham’s PCC ACCURA provides precise colour matching, pre-processing inspection, swift verification, product pattern recognition, completeness of products, coding accuracy, shipping, and surface inspection. And we ensure that the final product delivery is reliable with superior quality levels.
In the past few years, manufacturers used to merely focus on the final products and their quality factors. However, today quality assurance is in every phase of product development commencing from the manufacturing, production processes and right at the end of the packaging lines.
Shipper Weigher Solutions are a significant aspect of packaging quality control that makes sure both the manufacturer and the consumer are completely protected. Consumers get the fullest assurance that they are getting quality products whose ingredients have been precisely verified and accurately weighed as specified right on the packaging labels.
On the other hand, manufacturers get the quality assurance that their products are precise and comply with the regulatory benchmarks containing the correct quantities of products. Thus, Shipper Weighers are highly effective in building reliability between consumers and manufacturers by ensuring benchmarks are met and maintained throughout the packaging lines.
How Automating Shipper Weighing Can Assist in the Packaging Process?
Now, with the development of pioneering automated technologies, companies can get equipped to hold nearly 100% of mistakes. Meanwhile, Shipper Weigher Solution work meticulously, which means the automation capabilities to catch the errors and act on it are more beneficial, highly valuable, and quick to process. Blending with other automated equipment in the packaging process; this process provides highly trusted packaging for end-product users.
Further, Shubham Automation’s Shipper Weighers are embedded with advanced software that not only blends the precision and speed but even delivers in-depth analysis, which can even lend a hand in resolving challenges across the packaging lines.
Enabling Shipper Weighing at the End of the Packaging Line
A shipper weigher at the end of packing line makes the whole process complete, intact and precise in terms of accurate weight and packaging information. Automated lines can make production easy and straightforward, however, shipper weigher at the end of packaging makes packing full proof and highly comprehensive.
How Shubham’s Shipper Weighers Deal with Products with Stiff Packaging Tolerances
Products with rigid packaging tolerances with explicit dimensions can also be tracked by Shubham’s Shipper Weigher Solutions and can signal the requirements for packaging line adjustments if specific specifications are not met. Shipper Weighers are an integral part of manufacturing operations, making sure products that come in multiple packs are precisely intact and weighed accurately before they leave the manufacturing plants.
Today, most of the industries are re-checking their conventional legacy manufacturing solutions and packaging systems, specifically ones that faced operational challenges at the pandemic’s outbreak.
So, manufacturers and packaging organizations are turning to top technology providers like Shubham Automation to integrate Quality Assurance and Automation Solutions for facilitating their production, supply chains and packaging lines. The significant product transformations are already seen in market segments and industries, including Pesticides, Chemicals, Food & Beverages, FMCG, and Pharmaceuticals.
While manual inspections involve physical reviews of products and quality of workmanship, vision inspection systems use advanced cameras and image processing technology for parallel inspections. Shubham Automation’s developed automated vision inspection solution called PCC ACCURA plays a vital role in achieving comprehensive quality assurance and manufacturing control in diverse industries. This scenario further helps in reducing the overall manufacturing costs and ensuring a superior level of customer contentment.
Conventional vision inspections lead to lower speed processes, errors, and dependency on human resources. On the other hand, manufacturers are using automated vision inspection solutions in high-speed processes, higher magnification, 24/7 operations, and repeatability of tasks. A step further, automated technology offers machines and devices the capability to inspect scenarios or objects to make precise quality assurance decisions more accurately and swiftly.
Critical Applications of Automated Vision Inspection Solution by Shubham Automation
Our automated vision inspection solution PCC ACCURA provides advanced technology with enhanced performance image processing in required applications. Our solution offers accurate color matching, verification, pattern recognition, pre-processing inspection, verification, and surface inspection to ensure the delivery of consistent, higher quality products.
The PCC ACCURA solution enables completeness and correctness of products for example filled bottles in the Food, FMCG, and Pharma industry for challenges in the diverse check-points. These check-points cover loose cap, label inspection, label presence and absence, label mix-up as well as label position inspections. The assessments cover the checking of product dimensions, product defects, and label printing.
Further, the solution can be easily integrated with any of the packing line machines with modernized cameras and multiple lines right through our PCC ACCURA software and the latest hardware components. It uses an industrial PC with a touch display for the efficiency of operations and view.
The Advantages of Automated Vision Inspection Solution
The foremost benefit is the boost in product quality. Sample testing can be substituted with comprehensive and 100% quality checks reducing the overall review efforts. The manufacturer is entirely assured and can guarantee a 100% perfect product delivery, which is especially significant in safety-critical products.
Secondly, automated vision inspection processes can reduce the overall production costs, mainly when applied in early production stages. Most of the time, defective parts or components are removed from the production processes. However, in some cases, removed parts are automatedly re-introduced in the production process, saving material costs. So, vision inspection technology resolves the trade-off amid raising quality as well as cutting overall costs.
Its further benefits are as below
- Superior and higher speed inspection
- A lower percentage of mistakes and errors
- Comprehensive and 24×7 operations
- Less to no dependency on human resources
- Quick defect detection
- Tolerance inspection
- Alignment feedbacks
- Component measurement
- Part presence, absence, and orientation
- Swift print verification
- Avoids product recalls
- Reduces downtime
- Eliminates false-rejects
- Finally, it increases the production line efficiency
At Shubham Automation, we completely understand that all organizations require being the best. Further, we value their production efforts, manufacturing infrastructure, and costs to offer the needed quality output to lead their product categories successfully.
Our range of critical quality assurance solutions like PCC ACCURA facilitates organizations like you to put off errors, mistakes, defects, and issues that offer nothing but the best solutions to our clients and their end-users. We are always our client’s Quality Assurance Heads in any of the sectors or domains we provide our automated solutions.
Sustaining and enhancing quality assurance stays at the heart of any manufacturer who desires to create a long-lasting relationship with its customer base. So it is relatively more straightforward than if your target marketplace can rely on your capability to without fail produce products that meet their desires levels of quality.
The approaches used by companies vary across the board but eventually finding the most precise and cost-effective technique of offering quality assurance is the final objective. For quite a long time, the manual inspection of the manufacturing procedures was seen as a dependable approach to preserving quality standards. But even the most effective professional is prone to make errors, and the repetitive nature of the work adds to the cause of these mistakes.
How Vision Inspections can Enable High-Speed Production Lines
The technology has moved on very drastically over the past couple of decades, with modern 2D, 3D, and barcode reading systems increasingly utilized by diverse manufacturing companies. However, there is still some uncertainty from some companies being unsure with this techniques adding value. However, with the advances in technology, vision inspections can be carried out enormously quickly on high-speed production lines; more perfectly than a human can do it and with swiftness compared to the human eye.
Introduction of Standard Machine Vision Inspection Systems
Even with the introduction of standard machine vision inspection systems, there was some indecision around facilitating them into the currently active manufacturing processes. Despite the opportunity to trim down wastage and boost data surrounding the production line, they were seen as an inadequate solution, more expensive, and challenging to integrate into manufacturers’ current systems. Here is where PCC ACCURA, an Automated Vision Inspection Solution by Shubham Automation, came into the picture to overcome challenges.
PCC ACCURA – Automated Vision Inspection Solution by Shubham Automation
Recognized most excellently for its vision inspection systems, Shubham Automation’s automated vision inspection solution PCC ACCURA provides modernized technology with superior performance image processing in several applications particularly in production and packing areas.
Shubham’s PCC ACCURA offers accurate color matching, quick verification, pre-processing inspection, pattern recognition, completeness verification, coding correctness, shipping and surface inspection to ensure that the final delivery of products is consistent with higher quality.
PCC ACCURA is shaped as a tailored vision inspection system that performs for completeness and correctness of products for example filled bottles for challenges in the diverse check-points. These check-points include loose cap, label position and inspection, label presence and absence, label mix-up, and overprinting assessments for both the products’ front and back labels.
What are the Gains from Vision Inspection Solutions for Quality Assurance
A vision inspection solution that has been accurately installed and calibrated will be precise, quick, and trustworthy. Automated quality assurance and control with vision inspection solutions have many added business gains when matched to manual inspections. The former can run continuously 24 hours and 7 days a week, and it does not require any of the tea breaks. And further, it does not tend to suffer from fatigue like human resources do and are a lot more precise, saving additional time as well as efforts.
So, the time and monitoring efforts saved by running manufacturing processes 24/7 without any breaks or changing shifts cover the cost of automated vision inspection solutions very rapidly. Further, as per the global reports, the machine vision inspection market is liable to be a value of 15 billion USD by the year 2022.
On the same side, Shubham Automation with PCC ACCURA is constantly enhancing its technology year-on-year and facilitating manufacturers with a significant competitive edge. So, Shubham, with its PCC ACCURA vision inspection solution, promises to assure the quality assurance desires of all categories of organizations across the globe.
The objective behind effective quality assurance and a comprehensive inspection is to enable reliable products. Delivery of reliable products encourages your customer’s reliance and long-term loyalty. With our unique PCC ACCURA solution, which is an automated vision inspection system, we check an extensive range of properties to preserve the quality of your products. A step further, with its remarkable flexibility, versatility, and compliance, the solution can check numerous quality features defined by you or your clients.
Suppleness and Versatility in a Single Automated System
PCC ACCURA provides multiple application modules and work with multiple cameras for diverse check-points dealt by single software and hardware. It facilitates to inspect the presence of a range of components of the product, like package inserts, pipettes, blisters, and bottles, just as effortless as enabling the integrity of the packaging and contents.
At Shubham Automation, we can determine the practical module for the applicable vision inspection by having sample testing. On the other hand, for a comprehensive safety package, it is possible to blend quality control systems that enable identification tasks and fill inspections. This scenario facilitates us to make sure optimal quality inspection for your specific products. If required, even a 360° review model can be enabled by customizing our vision inspection solution.
A Bespoke Vision Inspection Solution Enables Versatile Check Points
PCC ACCURA is designed as a bespoke vision inspection system that performs completeness and correctness of filled bottles for confronts in the varied check-points. These check-points comprise the loose cap, label presence and absence, label position and inspection, label mix-up, and overprinting assessments for both the products’ front and back labels.
Criteria such as shape, color, and precise dimensions of the filling material can signify quality features just as much as uncovering contamination, foreign bodies, and overfilled blister pockets. Foils that are applied out of position or damaged demoralize customers’ confidence in your product and be safeguarded by vision control. Further, the solution can be applied to checking-out all types of cartons, pouch, containers, carboys, barrels, and bulk bags.
How PCC ACCURA Enables Quality Assurance with Prominent Benefits
The PCC ACCURA solution covers each control function and can be enabled as per individual customer needs without added technology efforts. This scenario minimizes the time needed to integrate the system and adjust it to new formats and control operations significantly and positively affects system accessibility and total operating costs (TCO).
PCC ACCURA can run constantly, and it does not need any of the tea breaks or suffer from fatigue like human resources do, saving added time, money, and efforts. The most prominent benefits that you can have if you choose PCC ACCURA are:
- Overall Cost Reduction
- Improved Uptime
- Production Enhancements
- Superior Inspection of Parts
- Complete Customer Contentment
- Boost Efficiency and Worth of Production Systems
Industries that highly utilize Automated Vision Inspection Solutions
At Shubham Automation, our several manufacturing clients from different industries are using PCC ACCURA as a solution to enhance the quality and security of their products. Some of the client industries are as below:
- Consumer Goods
- Chemical and Pesticides
- Food & Beverages
Finally, manually inspecting substantial defects is not always trustworthy and is highly labor-intensive. To overcome these restrictions, Shubham’s Automated Vision Inspection Solution PCC ACCURA utilizes image processing techniques that are compelling enough to advance quality and boost production rates drastically across different industries. So, PCC ACCURA delivers a higher performance inspection model for identifying defects and errors on a real-time basis with all applicable versatilities in a single system.
With the continuation of all the COVID-19 pandemic disruptions, the health and safety of our employees, partners, and the clientele at Shubham Automation is our highest priority. At the same time, the top management and employees at Shubham want to restate that we are always there for our stakeholders. Shubham Automation has been considered a significant technology and business unit even actively working for its clients during these challenging times. We are more loyal than ever to serve our customers with automated quality assurance solutions, many of whom are on and at the front lines against this COVID-19 crisis each day.
How Shubham Facilitates the Roll-Out of Vision Inspection Solutions even in COVID-19 Outbreak
At Shubham, we are the specialists in enabling superior Vision Inspection Systems that provide state-of-the-art technology and automated quality. Our newest generation of vision inspection solutions is enhanced in every way to be swifter, more hygienic, safer, competent, integrated, and effortless to maintain. No matter how you select to look at it, we have got you covered with all the technical features and business functionalities, even enabling social distancing measures as a quick response to the COVID-19 Outbreak.
Automated vision inspection solutions are built to cater to numerous quality assurance processes such as packaging, manufacturing, sorting, assembly lines and other automation applications. These solutions have been shaped to meet superior and high-speed quality control requirements for the complete range of product inspections.
The key to Shubham’s capability to produce such quality Vision Inspection Solutions and roll-out them globally is our detailed design process. Every solution we design has reliability, steadfastness, and effortlessness in use applicable to your product requirements. This is a diverse approach compared to most of the market leaders and competitors who don’t take the time to purposely design every solution so that it can be customized and straightforwardly rolled out. We go all the way through similar but personalized design procedures for a diversity of systems, and this is what allows us to roll-out our quality assurance solutions across the globe.
PCC ACCURA – Automated Vision Inspection Solution by Shubham Automation
Known best for its vision inspection systems, Shubham Automation’s automated vision inspection solution PCC ACCURA offers cutting-edge technology with superior performance image processing in needed applications. This incorporates automated inspection and identification, answering to all the quality control problems. Further, our vision inspection solutions offer precise colour matching, verification, pattern recognition, pre-processing inspection, completeness verification, and surface inspection to our customers to ensure the delivery of reliable, high-quality products.
Shubham’s PCC ACCURA is designed as a custom vision inspection system that performs for completeness and correctness of filled bottles in Food, FMCG and Pharma industry for challenges in the following check-points which cover loose cap, label inspection, label presence and absence, label mix-up, label position and over printing inspections. These inspections are for both the front and back labels of the specific products.
A step further, our PCC ACCURA solution can be effortlessly integrated with any of your packing line machines. It is incorporated with several modernized cameras and numerous lines right through our PCC ACCURA software and advanced hardware. It utilizes industrial PC with a touch display for the effectiveness of operations and view.
Key Application Benefits of PCC ACCURA Solution
So, PCC ACCURA not only enables quality assurance, but also boosts line accuracy, which avoids product recalls, reduces downtime, eliminates false-rejects, and thereby persistently increases production line efficiency. Our solution is applied for checking-out all categories of bottles, cartons, pouch, containers, carboys, barrels, and bulk bags. Further, our PCC ACCURA solution enables automation at every level with round the clock processing, minimize manpower and use of additional resources.
Shubham Automation supports you for global roll-outs with benchmarked quality assurance solutions, automated systems, advanced technology and a fool-proof solution development methodology. All these initiatives and assurances consider all the aspects required to create a successful roll-out. Our vision inspection solutions promise to satisfy the desires of all categories of organizations around the globe, moving ahead with a strong response to the COVID-19 Outbreak.
The average cost of a product recall in specific industries is in millions when we measure the overall time, efforts, and costs of recovering the recalled products. Additionally, these expenses are even more costly when we consider the final consequences of product recalls. A lost market share, the effect on customer loyalty and several other concerns must be thoroughly counted to evaluate a recall’s impact on your company brand.
Despite the underlying problems that are sources to product recalls, there is no particular reason why recalls should be as regular as they are today with advanced infrastructure and the latest technologies. Organizations should take the assistance of right vision inspection solutions that are highly competent in finding and reporting problems before these products finally leave the plant. In this particular blog, we will discuss and explore the significant impact product recalls can have on a company brand and suggest solutions to keep away from future product recalls.
Harmful Impacts of Product Recalls
- Involved Costs
Let’s initiate with costs. The cost of a product recall is not equivalent to the cost of the exhausted product alone. It also comprises the costs of precisely finding, transporting, and demolishing that particular product, plus the expenses linked to your supply chain’s distraction. All these cost factors incorporate business interruption, reverse logistics, alerts to relevant parties (customers, supply chain, regulatory bodies, and consumers) along with added labor costs to perform all these tasks which have not been included in the budget by the involved stakeholders.
- Customer Loyalty
When customers lose reliance on a company brand, it eventually translates to losses in sales and reduction in market share, mainly if the product recall is because of undeclared ingredients and allergens. In a recent report by the food industry, around 55 percent of consumers said they would provisionally or temporarily switch brands due to a product recall. Furthermore, about 15 percent said they would by no means buy the recalled product for a second time, and around 21 percent would shun buying any product from that specific brand.
Further, even if you don’t face a product recall, unsatisfactory experience with your product because of factors like mislabelling or miscoded products will impact the brand and hurt its probability of becoming a successful product with momentous sales.
Frequent Causes for Product Recalls
Despite the efforts, time, and expense connected with correcting these problems, recalls are not at all rare. According to surveys and reports, there have been a high number of recalls each month due to labelling mistakes alone so far in the year 2020. The frequent issues for recalls comprise:
- Undeclared Allergen Information: Whether allergen information is scribbled or expelled from the packaging.
- Mismatched Product and Packaging: Packaging is executed with the incorrect product version by error and has to be recalled.
- Mislabelled Lids and Packaging: The lids or labels are made functional to the mistaken packaging, which outcomes in the form of a recall.
Enhancing traceability for swifter identification and reporting of these problems can assist you in evading expensive product recalls and trim down products as well as plastic wastes.
How to Avoid Product Recalls
Finally, coming to the solution of this problem, Shubham Automation, with a decade of experience designing Vision Inspection Systems has developed and enabled an automated vision inspection solution called PCC ACCURA.
PCC ACCURA is compact and state-of-the-art designed product which can be easily integrated with any of your packing line machines. It is integrated with multiple advanced cameras and numerous lines right through our smart eye software. It uses 15.6 inch industrial PC with a touch display for simplicity of operation as well as view.
Further, it utilizes modernized tools and advance illumination for precise reading on shiny surfaces. It acts like an intelligent eye checking solution for comprehensively checking-out the final packaging information on products to uphold information correctness rather than depending on human resources to execute this job manually.
The solution advances and boosts line accuracy as well as quality assurance. It avoids recalls, trims down the overall downtime, false-rejects, and declines any type of rework, thereby continuously increasing production line efficiency.
PCC ACCURA facilitates several specific categories of automated inspections. Here are a few we have included:
- Enable checking of all types of cartons, bottles, pouch, containers, carboys, barrels, and bulk bags for finding errors.
- Printed batch code and expire code is examined to confirm whether it is completely precise or not.
- The solution can ensure the cap fitting, cap pop-up, label presence, and complete alignment.
- It can also identify a mix match of labels and products in the explicit shipper.
- Finally, it facilitates reports such as precise performance reports, audit trail reports, batch-wise reports, hourly reports, production reports, and specific fail image analysis.
At Shubham Automation, our range of quality assurance solutions like PCC ACCURA facilitates organizations like you to prevent recalls for your brand that deliver nothing but the best experience to the client, the involved supply chain stakeholders, and the end consumer.
Our dynamic quality assurance team is always our client’s default Quality Assurance Heads with complete responsibilities in any of the sectors or domains we provide our automated solutions.