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Packaging & FMCG – Genesys

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INDUSTRY • Packaging & FMCG

Every pack, checked before it leaves the line.

Packaging and FMCG lines run fast, run long, and give a consumer exactly one chance to trust what’s on the shelf. Tech Genesys builds machine vision inspection around your line to catch label, cap, seal, fill, code, and packaging defects in real time — before a bad pack becomes a returned pack, a retailer rejection, or a recall.

Discuss Your Inspection Requirement
Explore Our Vision Solutions
inspection checkpoints per pack
0
online, in-line inspection — no sampling
0 %
typical capture-to-decision time
< 0
continuous line monitoring & logging
0 /7

A single missed defect travels a long way in FMCG.

Packaging errors don’t stay on the line — they reach a retailer’s shelf, a consumer’s home, or a recall notice. High-speed filling and packing lines leave no time for manual double-checks, and the cost of a miss is rarely limited to one unit.

Retailer & compliance rejections

Modern trade and export buyers audit label accuracy, barcode readability, and GS1 code compliance before a batch is accepted

Consumer safety exposure

A broken induction seal, missing cap, or leaking closure can reach a consumer before anyone on the line notices.

Brand & recall cost

Wrong labels, wrong MRP, or an unreadable expiry date can trigger a market withdrawal far more costly than the pack itself.

Line speeds outpace people

Filling and capping lines running hundreds of packs a minute leave no realistic window for manual visual checks.

Fill accuracy & giveaway

Consistent under- or overfill affects both legal-metrology compliance and product cost across a full production run.

Multi-SKU changeovers

Frequent SKU, label, and pack-size changes on shared lines increase the chance of the wrong label reaching the wrong pack.

Nine checkpoints, one pass/fail decision per pack.

Each checkpoint below can run independently or as part of a single combined inspection station, matched to your pack format, line speed, and existing reject mechanism.

Label Inspection

Verifies correct label artwork, placement, skew, and print clarity — flags missing, wrinkled, torn, or misaligned labels before they leave the labeller.

Cap & Closure Inspection

Confirms cap presence, correct type, proper seating, and orientation — catching loose, cross-threaded, tilted, or missing caps.

Seal Integrity

Checks induction seals, tamper bands, blister seals, and pouch seals for continuity — identifying breaks, wrinkles, or incomplete seals that risk leaks and contamination.

Fill Level Verification

Measures liquid or powder fill height against target range — detecting underfill and overfill for legal-metrology compliance and consistent product cost.

Container Inspection

Inspects bottles, jars, cans, and cartons for cracks, deformation, discoloration, short shots, and foreign particles before filling.

Printed Code Verification

Reads and verifies batch codes, expiry dates, MRP, and barcodes / QR / DataMatrix codes via OCR and OCV, even on curved or reflective surfaces.

Product Presence Check

Confirms every cavity, pocket, or unit is filled — in multipacks, blister cards, cartons, and case-pack configurations — flagging any missing item.

Orientation Detection

Checks that caps, labels, and products face the correct direction for downstream cartoning, sleeving, and palletizing operations.

Packaging Defect Detection

Identifies crushed cartons, torn flaps, shrink-wrap defects, and secondary-packaging damage before cases move to dispatch.

Inspection tuned to your pack format.

Optics, lighting, and inspection logic change with the format — a reflective blister card is not lit like a matte carton. We select the right approach for each.

Bottles & Jars

Cap, seal, fill level, label, and body defect checks on glass and PET.

Cartons & Boxes

Print verification, flap closure, and carton damage inspection.

Pouches & Sachets

Seal continuity, fill level, and print registration on flexible film.

Blister & Clamshell Packs

Cavity-by-cavity presence checks and seal-edge inspection.

Cans & Tubes

Seam integrity, print quality, and code readability on curved surfaces.

Multipacks & Cases

Unit-count verification and outer-case condition checks pre-dispatch.

Complimentary Feasibility Evaluation

Ready to inspect every pack on your line?

Share your pack format, defect history, line speed, and existing reject setup. Our application team will map out the right checkpoints and camera architecture for your line.

Discuss Your Application
Component • Defect • Cycle Time • Accuracy • Existing Machine

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