Verifying Cap-and-Seal Integrity


Before bottles and tubs are packed and shipped, caps and safety seals must be verified. Misapplied lids, uneven seals, or damaged rims cause leaks, rework, and brand risk. In-line 3D profiling and 2D smart-camera vision measure cap height and level, check that tamper-evident seals are present, and assess sealing surfaces for flatness. The system flags defects in real time to trigger the removal of defective goods, protecting consumers, cutting waste, and maintaining throughput with consistent, traceable records.

Aurora Design Assistant  on a computer screen in a packaging manfucturing facility.

Automate cap and seal inspection with in-line 3D profiling and vision to prevent leaks, protect brands, and keep lines moving

Zebra AltiZ 3D Profiler for Food and Beverage Bottle Cap Alignment

Verify cap positions with 3D sensors

AltiZ 3D profilers create a 3D profile of caps, lids, and sealing rims at production speeds, then compute height and tilt to verify correct application. The sensors measure whether a cap sits level, confirm the presence of tamper-evident features, and assess sealing-surface flatness that affects leak integrity. Built for production environments, Zebra AltiZ 3D profilers deliver stable measurements on bottles and plastic tubs, enabling teams to detect defects early and remove only nonconforming units.

Zebra Iris GTX Scanning Fill Level in Pharmaceuticals

Perform 2D cap-and-seal inspection

Iris GTX smart cameras perform high-speed 2D inspections to validate cap presence and seating, detect cocked or cross-threaded closures via edge and circle measurements, confirm that tamper-evident bands or shrink sleeves are present and intact, and check foil seals for wrinkles or tears. The cameras can also highlight chips, dents, or product contamination along the rim that would compromise product quality. With peripheral lighting and C-mount lens options, the Iris GTX can be configured to handle reflective closures and clear films while maintaining line-rate throughput.

Screenshot of Aurora Design Assistant vision system detects cap misalignment and seal integrity failures on bottled products.

Verify caps, seals, and surfaces with 3D and 2D vision tools

Aurora Design Assistant machine vision software processes 3D and 2D images, applying programmed logic to give pass/fail decisions on inspected bottles. Engineers use a wide range of field-proven vision capabilities to configure inspection flows that incorporate inputs from 3D profilers and Iris GTX smart cameras to confirm proper cap application, verify seal presence and continuity, and check rim condition and sealing-surface flatness. Configurable error handling logic, such as alarms, retries, and safe rejects, triggers a programmable logic controller (PLC) or reject mechanism in real time. This helps keep bad products out of downstream packing processes.

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