A visual inspection system based on image processing captures and analyzes images in real time to identify defects on products. This solution has been widely deployed in manufacturing plants to detect foreign matter, flash, silver streaks, short shots, as well as printing or labeling defects on plastic products.

In plastic manufacturing, automated visual inspection enables scratches, stains, and surface defects to be detected immediately as products are released from the mold.

ViSCO’s solution uses super-depth cameras combined with machine vision inspection system VTV-9000, and can integrate AI technology to identify complex defects that do not strictly follow predefined training data.

Automated Visual Inspection Using AI Vision Cameras

The automated visual inspection system combines high-resolution industrial cameras, dedicated lighting, and image-processing software. Plastic products are captured from multiple angles, and the acquired images are analyzed using specialized detection algorithms (such as DefFinder, Scratch/Foreign Matter Filter, etc.) to identify surface defects.

ViSCO technology further enhances this capability with AI Vision. Using VTV-AI Studio, the software learns from images of good samples and automatically classifies defective products. As a result, the system can evaluate defects even when they have not been explicitly taught in advance—for example, detecting foreign objects appearing at unpredictable locations.

In addition, ViSCO’s VTV-9000 system supports both conventional rule-based inspection and AI-based inspection simultaneously. These two approaches complement each other, delivering more reliable and accurate detection of visual defects.

Unlike conventional cameras that must be positioned directly in front of the product, ViSCO’s super-depth cameras can be mounted at a 45-degree angle or from virtually any direction while still keeping the entire product surface in focus. This provides greater flexibility when designing production lines. 

The system also employs high-sensitivity cameras and sophisticated image filters that suppress glare and reflections on glossy surfaces, making it possible to detect extremely small foreign particles or subtle defects on injection-molded plastic parts.

Applications in Plastic Product Visual Inspection

Detection of Misaligned or Lifted Labels on Plastic Bottles

In injection-molded plastic processes, labeling can result in misalignment or peeling. Conventional side-mounted cameras are often obstructed by conveyor frames, but ViSCO’s solution uses super-depth cameras installed at an angle, maintaining sharp focus across the entire label surface.

The system continuously captures images as products move along the line, automatically identifies label positions, and detects misalignment or tearing. With the ability to inspect eight bottles simultaneously (4 products × 2 lines) at high speed, the system ensures complete inspection coverage without slowing down production.

Inspection of Foreign Matter and Black Spots on Plastic Surfaces

Plastic products with glossy surfaces—such as white bottles or housings—often reflect light strongly, making defect detection difficult. ViSCO addresses this challenge by rotating the product and using two super-depth cameras positioned at different angles to repeatedly capture both the front and back surfaces. 

By combining images from multiple angles, the system effectively inspects all six sides using only two cameras instead of six conventional ones. Optimized lighting conditions eliminate glare, while dedicated foreign-matter detection tools enable reliable identification of black contaminants even in reflective areas.

Visual Inspection of Pharmaceutical Bottles and Containers

For cylindrical products such as medicine bottles with graduation marks, inspection must cover the entire side surface. While traditional systems rely on line-scan cameras, ViSCO uses fixed area cameras combined with product rotation. 

Multiple images are captured along the height of the bottle during rotation and then stitched together to form a complete circumferential image. This approach is more cost-effective than specialized line-scan cameras and simplifies focusing and lighting adjustment. ViSCO’s algorithms ensure accurate image stitching even when the bottle axis is slightly off-center, allowing precise detection of foreign matter and black spots on the full circumference.

Inspection of Infusion Bag Valves Under Sterile Conditions

In medical applications, infusion bags or drug-packaging components must undergo extremely strict visual inspection while maintaining sterility. For example, the connection port of an infusion bag must be checked for black spots, discoloration, short shots, or deformation on both inner and outer surfaces. 

ViSCO designs fully automated systems using multiple cameras and specialized lenses arranged around all required inspection angles, combined with flexible rotation and orientation control. This eliminates human intervention while ensuring that every surface of the part is inspected automatically. The system is customized based on technical requirements such as defect criteria, space constraints, and budget to meet the highest inspection standards in the pharmaceutical industry.

Continuous In-Line Inspection on Conveyors

Another common scenario involves continuous, non-stop inspection in a flowing process. For example, detecting black spots on white boxes moving continuously along a conveyor. ViSCO installs four cameras at fixed angles around the inspection area to capture images as products pass through. 

Using super-depth technology from four directions, the system acquires detailed surface images without stopping the production line. Even though white surfaces often create strong gradation and glare, ViSCO’s specialized image-processing software can reliably distinguish true defects from reflections.

Other Visual Inspection Applications

• Injection mold monitoring
• Detection of foreign matter and black spots on packaging
• Printing inspection and defective bottle cap sorting
• Inspection of PET bottle cap bridges
• Detection of flash, short shots, and foreign matter
• Detection of blurred or unclear characters

Benefits of Applying ViSCO Systems in Plastic Production Lines

1. Inspection Without Interrupting Production

ViSCO camera systems can continuously scan products on conveyors without stopping the line. For example, the label misalignment inspection solution uses a moving robot and super-depth cameras to inspect eight bottles simultaneously (4 × 2) at high speed without reducing line throughput. 

2. Detection of a Wide Range of Defects

With a comprehensive set of image-processing tools, ViSCO can detect common injection-molding defects such as foreign matter, black spots, flash, short shots, silver streaks, and misaligned or torn labels. Thanks to machine learning capabilities, the system can also identify complex defects without relying solely on fixed inspection rules.

3. Reduced Cost and Space Requirements

In scenarios that traditionally require multiple cameras for full coverage (for example, six cameras for six sides of a plastic box), ViSCO uses only two angled super-depth cameras combined with product rotation. This reduces the number of cameras by nearly two-thirds, lowering equipment costs and installation space. The compact design is ideal for factories with limited floor space.

4. Compliance With Cleanroom Requirements

For medical plastic products such as syringes, medicine containers, and infusion bags, sterility is critical. ViSCO systems can be fully automated without human contact. With multiple cameras and specialized optics arranged around the part, all surfaces—inside, outside, neck, and bottom—can be inspected while maintaining a sterile environment.

5. Easy Operation and Maintenance

Customer feedback indicates that ViSCO systems are easy to deploy without complex programming. Operators only need to register a small number of good samples, after which the system learns automatically and applies the inspection criteria in production. 

6. High Accuracy and Flexibility

ViSCO’s super-depth technology captures images with clarity comparable to human vision. A single capture can acquire data from multiple product surfaces at once, reducing image acquisition time. In addition, ViSCO offers more than 70 specialized image-processing tools and flexible options for lenses and lighting to meet diverse inspection requirements.

Why Choose ViSCO

ViSCO systems integrate high-speed hardware with proprietary software, enabling fast processing, high-resolution camera connectivity, and image storage. The software offers over 70 inspection tools and is easy to configure and operate even without deep expertise in image processing.

ViSCO’s optical design philosophy prioritizes capturing the optimal inspection image before applying image-processing algorithms, achieved through the proper selection of cameras, lenses, and lighting.

Super-depth cameras allow angled imaging similar to human visual inspection while keeping the entire surface in focus, significantly improving inspection accuracy. The system learns from multiple good samples to define a statistically “acceptable product,” and then focuses on detecting defects such as foreign matter, stains, and scratches.

Temas is the official distributor of ViSCO products in Vietnam. We support customers with training and system calibration during commissioning. If you are interested in ViSCO solutions or would like to discuss a real-world inspection challenge, please contact Temas

.