What is Trident Solution for Tobacco Industry
Trident’s Vision Intelligence Systems system uses advanced imaging technology to identify and detect defects in tobacco products. The system is designed to detect a wide range of defects, including uneven tobacco distribution, broken or crushed tobacco leaves, foreign objects, discolored or damaged packaging, price tags, barcode, expiry date, and more.
The system is fast, accurate, and reliable, making it an essential tool for any tobacco manufacturer. The system uses high-resolution cameras to capture images of the tobacco products as they move along the production line. The images are then analysed using sophisticated algorithms to detect any defects or anomalies.
The importance of Vision Intelligence Systems in Tobacco Industry
Vision Intelligence Systems plays a critical role in the tobacco industry. The tobacco industry is highly regulated, and manufacturers must comply with strict quality and safety standards to ensure that their products are safe for consumers. Vision Intelligence Systems is an essential part of the manufacturing process because it helps manufacturers identify and detect defects in their products before they are shipped to retailers and consumers.
Defects in tobacco products can have serious consequences for consumers. For example, broken or crushed tobacco leaves can result in a harsh and unpleasant smoking experience. Foreign objects, such as pieces of metal or plastic, can be dangerous if inhaled. Discolored or damaged packaging can be a sign of moisture or other contaminants, which can affect the quality and safety of the tobacco product.
Benefits of Trident's Vision Intelligence Systems
Improved Product Quality
The primary benefit of visual quality inspection is improved product quality. By using advanced imaging technology, manufacturers can identify and detect defects and imperfections in their products.
Increased Efficiency
Automated visual inspection systems are faster and more efficient than manual inspection. Our system can inspect thousands of tobacco products per hour, making it a fast and efficient way to ensure the quality and safety of tobacco products.
Reduced Costs
Automated visual inspection systems can reduce costs by identifying defects and imperfections early in the manufacturing process. This can help prevent the production of defective products, which can be costly to the manufacturer.
Compliance with Regulations
Trident’s VIS can help manufacturers comply with these regulations by ensuring that their products meet the required standards for quality and safety.
Trident VIS Solution used AI & Cameras to identify any defects, such as misaligned text, damaged packaging, or any other quality issues.
Trident’s Automated Visual Intelligence Systems can also monitor the manufacturing process itself by analyzing images and data from sensors to identify any deviations or abnormalities. This helps manufacturers to identify and correct issues before they lead to defects or quality issues in the final product.
can also be used to monitor the packaging process to ensure that cigarette packets are correctly sealed and labeled. This helps to prevent issues such as contamination or incorrect labeling, which can lead to recalls or customer complaints.
Setup of Cameras at Plants
Camera vs Defect Mapping
| Sr. No | Cameras | Inspection of Defects |
| 1 | Cam-1 | 1- Inner Frame Mis-align/ Absent 2- Foil Damage / Crushed / Absent |
| 2 | Cam-2 | 1- Short Mitre 2- Long Mitre 3- Lid Damage |
| 3 | Cam-3 | 1- Short Mitre 2- Long Mitre 3- Smiley 4- Bottom Panel Damage 5- OCR |
| 4 | Cam-4 | 1- Top Misalign/Absense 2-Open Wrap 3 – Wrinkles |
Implementation
Image Acquisition:
- Images will take at Client Plant by 4 cameras for cigarettes packets, a total of 2000 images will be taken from each camera for capturing all sides
- Therefore, 4 cameras were used to capture all 6 outer sides, 1 inner side & 1 wrapping film of cigarettes packs.
Image Pre-processing:
- Image Annotations:
- Defects were manually highlighted on the images.
Model Training and Validation:
- Model training will be done in an iterative manners until high reliability results will be achieved.
- For price checking OCR will be used to read the price from the bottom panel.
Process
Trident’s VIS solution uses high-resolution cameras to capture images of the cigarette sticks manufacturing process. These images are then analyzed using AI to identify any deviations or abnormalities, such as equipment malfunctions or defects in the cigarette materials, wrong quantity of tobacco, misaligned paper, Filter length, etc. If an issue is detected, the system automatically alerts operators, allowing them to identify and correct the problem before it leads to defects or quality issues in the final product.
Use Case – One of Largest Cigarette Manufacturer Using Visual Quality Inspection to Identify Defects
- Client produces cigarette sticks at a very high speed 12000 cigarettes / min.
- The cigarette has 2 parts i.e., PCT and cigarette paper. Customer wants to inspect both the parts with complete 360-degree coverage.
- Their existing system is only capable of inspecting the PCT part and that too the only side that is facing the camera. Rest area remains uninspected.
- Existing system also skips some cigarettes because of the high speed.
- Existing system faces difficulties whenever the PCT is of white color. Due to this it is difficult to tell the length of PCT.
- So, Client wants to replace the existing system with new solution that checks for defects in entire cigarette
Scope of Work from Largest Cigarette Manufacturer
Solution Approach
- Since the cigarettes are placed on the rotating motor drum inside the machine through vacuum, there is a requirement of 2 cameras each to capture 180 degree of the cigarette.
- These 2 cameras will be inspecting the 2 different sides of the cigarettes at different locations.
POC Results
Here are some reasons why you should choose Trident for your visual quality inspection needs
Improved Product Quality
Trident’s visual inspection system uses advanced imaging technology to identify and detect defects in tobacco products. Our high-resolution cameras capture images of the tobacco products, which are then analyzed using advanced software that can detect defects and imperfections. foreign objects, and discolored or damaged packaging.
Fast and Efficient
Trident’s visual inspection system is fast and efficient, making it an essential tool for any tobacco manufacturer. Our system can inspect thousands of tobacco products per hour, ensuring that your products meet the required standards for quality and safety. This can help reduce costs by identifying defects and imperfections early in the manufacturing process.
Customizable Solutions
At Trident, we understand that each manufacturer has unique requirements and challenges. That’s why we offer customizable solutions to meet the specific needs of our clients. Our team will work with you to design a visual inspection system that meets your requirements and helps ensure the quality and safety of your products.
