FASTER, SMARTER, AND MORE EFFICIENT QUALITY CONTROL AND PACKAGING PROCESSES
In industries like food production, where product variability and external variables and fluctuations are high, ensuring consistent quality control is a constant challenge. Although quality control was initially implemented for end-product inspection, businesses are also increasingly recognizing its value in earlier stages of production. By integrating vision inspection throughout the process, manufacturers can achieve comprehensive product monitoring and improve handling and packaging efficiency like never before.
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Artificial Intelligence
and Self-Learning
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SENSURE SYNAPSE utilizes Artificial Intelligence algorithms and self-learning approach to classify products as compliant or non-compliant and identify defects and irregularities. This guarantees best-in-class quality control and maximizes packaging efficiency, even in highly variable environments, without the need for time-consuming manual classification and setup. However, the operator remains in control, with the possibility to manually adjust thresholds and select key features whenever needed, providing a flexible balance between automation and human oversight.

SENSURE SYNAPSE learns on its own, directly on the line and adapting to production variables in real-time: it automatically proposes quality recipes and tolerance limits for each identified features based on live production data, saving time and reducing human error, allowing the operator to make subsequent modification. This capability ensures operators can fine-tune and adjust thresholds or define critical features to maintain full control over the process. This brings unprecedented simplicity and control, which traditional systems cannot match.

One of the key advantages of SENSURE SYNAPSE is its transparency. Unlike other AI systems that operate as black boxes, the SYNAPSE provides clear explanations for its decisions, offering complete insight into how it determines whether products pass or fail quality checks.

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Main quality features measurable with SENSURE SYNAPSE
  • Shape/size (min/max/average diameter, perimeter, length, width, roundness, area, etc.), compactness, cracks/holes detection and their conformity
  • Color on top (color, spot detection, etc.) and/or bottom (color, burnt areas, flour marks, spot detection, foreign color anomalies in general), edge/contour defects
  • Topping and seeding conformity (quantity, distribution, and color), texture analysis
  • Height/thickness (min/max/average), flatness, planarity, volume, slope/symmetry
  • Foreign body detection (identification is possible if the dimension and color differences of the inclusions are detectable in the camera)
  • Moisture
  • Temperature
Possibility to develop ad-hoc quality features upon feasibility assessment.
Rejection mechanisms

Choosing the right rejection mechanism is important step to ensure non-compliant products are properly removed from the line even at very high speed. The choice depends on several factors, including type of products (dough, baked, with/without topping, etc.) and dimensions, line width and throughput rate/speed, products pattern required (before and after rejection), where non-compliant products need to be directed (conveyor, bin, etc.), space available, etc.

Some examples of the different rejection mechanisms include:

  • Conveyor shutdown or alarm
  • Air jet with nozzles (from top, bottom or lateral)
  • Traps (with linear movement, hinged, etc.)
  • Retractable belts
  • Pusher (with air cylinder)
  • Swing gate
  • Robots