KHS, a German turnkey systems provider, has integrated AI into its Innocheck TSI closure inspection unit for tethered cap compliance.

Since 2024, tethered caps have been mandatory for all nonreturnable polyethylene terephthalate bottles in the EU, which has led to an increase in the variety of closure designs and the demand on inspection technology.

The Dortmund-based company noted that the introduction of tethered caps has required bottle and beverage producers in the EU to adapt to ensure product quality and protection.

The growing number of bottle and cap design variants, combined with increasing line capacities, has further complicated inspection processes.

KHS added that its AI-based fault detection system for tethered caps uses patent-pending algorithms to analyse high-resolution images of bottle closures in real time.

Cameras capture detailed visuals, which AI models evaluate, employing deep learning to adapt to new types of defects.

This system enhances both the accuracy and efficiency of inspections.

Designed specifically for the Innocheck TSI cap inspector, the AI module is compatible with both new and existing machines.

KHS plans to extend AI applications to additional inspection technology equipment in the future.

KHS labelling and inspection technology product support executive Nikita Wall said: “Tethered caps were rarely used before the EU directive came into force. Conventional systems thus frequently reach the limits of their capacity where cap inspection is concerned.”

“Our customers make extremely high demands of quality assurance. In intensive field tests, our AI-based fault detector has proved that it fully meets these requirements.

“In the development team, we’re currently discussing which systems this would make sense for. AI solutions are only practical where the requirements are complex -and if they give our customers clear benefits.”