In-line Inspection System for Leak Detection and Contaminants Analysis in Returnable Water Jugs

The use of rigid plastic jugs for the distribution of mineral water is a well-established practice in the industry, with a positive environmental impact thanks to the returnable bottle system. However, reusing containers presents significant challenges in terms of hygiene, quality, and safety. Companies must ensure that jugs returned by users are free from contaminants and structural damage to avoid the risk of water contamination, product loss, or inefficiencies in the production process. In this context, technological innovation plays a crucial role in supporting a safe and efficient process.

INLINE INSPECTION: THE KEY TO A SAFE PRODUCT

The jugs are returned to bottling companies by users to be refilled. This offers environmental benefits, but to ensure product hygiene and safety, bottling companies must carry out appropriate quality controls. The company must be certain that the jug is not damaged, has not been misused, and does not contain foreign materials. Antares Vision Group's Empty Jugs Inspection solution is capable of checking, at line speed, for the presence of cracks, such as holes, micro-holes, or fractures, as well as chemical contaminants, even in trace amounts, using electrochemical and pressure sensors. This way, it is possible to prevent product loss due to cracks or fractures and ensure the consumer the safety and quality of the jug.

HOW THE INSPECTION SYSTEM WORKS

The jugs may have been improperly used and could have contained waste materials or other liquids different from water. We do not know what substances or products might have been introduced into them. To detect the presence of chemical contaminants, target molecules representative of certain substance categories have been identified. If detected, these molecules indicate improper use of the jug. The inspection process begins with a leak test by measuring pressure drop, applying controlled pressure, and monitoring its retention. This ensures that the container does not have microcracks or weak points that could cause problems during the filling/production phase, product loss during transport, or damage to dispensing devices. Immediately afterward, the system performs air suction from the jug. Special sensors, sensitive to odor compounds, quickly detect the presence of traces, residues, or even just odors of harmful substances such as: solvents, hydrocarbons, ammonia, sulfurous odors, food smells, detergents, etc.

INNOVATIVE INSPECTION: LEAK AND CONTAMINANT SYNERGY

One of the main innovations introduced by the Empty Jugs Inspection solution is the integration of a leak detection system with a contaminant detection system in a single machine, using special sensors and algorithms specifically designed to detect extremely small defects by leveraging the synergy between the two inspections. The inspection system allows real-time data transmission to support statistical analysis and rejection data. This enables optimized and immediate management of the production process, improving efficiency and minimizing rejects. Additionally, the solution is fully modular, able to adapt to different production speeds and include additional controls. Besides checking for cracks or holes and volatile substances, it is possible to monitor the sidewalls of the jug, the presence of foreign objects, defects in the neck finish, and the correctness of the labeling in terms of positioning, presence of codes, writing, and brand logo.

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