X-Ray systems and Vision systems are the two main technologies for inspecting containers in industries like food, beverage, and pharmaceuticals.
Key Differences:
Quick Comparison:
| Feature | X-Ray Systems | Vision Systems |
|---|---|---|
| Inspection Type | Internal (density detection) | External (camera-based) |
| Key Capabilities | Detects hidden contaminants, fill levels | Checks labels, caps, surface defects |
| Best For | Glass, metal, or plastic (internal) | Glass, metal, or plastic (external) |
| Speed | High-speed (up to 2,400 cans/min) | Varies by setup complexity |
| Limitations | Struggles with dense products | Cannot inspect internal contents |
Pro Tip: Many manufacturers combine both systems for full quality control.
Read on to see how these systems work, their applications, and how to choose the right one for your production line.
X-Ray systems rely on electromagnetic radiation to spot density differences, making them ideal for finding hidden defects and contaminants inside containers.
They can detect materials like ferrous and non-ferrous metals, glass, stones, rubber, hard plastics, and even bones.
Typically placed right after the seamer, these systems handle high-speed production lines - processing over 1,000 food cans and 2,000 beverage cans per minute. They also allow for real-time defect removal and continuous monitoring of the filler and seamer processes.
Vision systems use cameras paired with controlled lighting to perform exterior inspections. They are particularly effective for:
These external checks work alongside X-Ray systems to ensure containers meet all visual quality requirements.
Up next, we'll break down how X-Ray and Vision Systems compare in areas like detection capabilities, processing speed, and cost.
X‑ray systems rely on density contrast to identify internal defects and contaminants. In contrast, vision systems use high-resolution cameras and controlled lighting to inspect external features.
| Characteristic | X‑Ray Systems | Vision Systems |
|---|---|---|
| Inspection Type | Internal inspection using density detection | External surface inspection |
| Detection Capabilities | Detects rigid foreign materials (metals, glass, ceramics, bones, some plastics), fill-level issues, and missing items | Checks labels, prints, caps/closures, surface damage, color/gloss variations, and external contamination |
| Container Compatibility | Works with glass, plastic, or metal packaging, including metallized films | Suitable for glass, plastic, and metal containers (external) |
| Throughput | High-speed inspection for fast production lines | Varies based on inspection complexity and camera setup |
| Environmental Factors | Unaffected by product temperature changes | Needs controlled lighting conditions |
| Maintenance & Lifespan | Moderate to high maintenance; lifespan of 5–10 years | Lower maintenance requirements |
| Limitations | Struggles with very dense products or extreme thickness variations | Cannot evaluate internal contents |
X‑ray systems are particularly effective for inspecting metallized films and metal containers, tasks that vision systems cannot handle. Because of this, manufacturers often combine the two: vision systems for external checks and X‑ray systems for internal inspections like fill levels and contaminants. Next, we’ll dive into how each system performs in specific applications.
Building on the performance comparison, here's how each system is best utilized:
Vision systems are ideal for fast-paced external inspections, especially for spotting surface defects. These systems are commonly used for:
FILTEC's OMNIVISION 4, powered by the INTELLECT platform, performs these inspections efficiently at production speeds.
X-Ray systems are designed for inspecting the internal contents of sealed containers. Their primary uses include:
FILTEC’s Photon Level Inspection system uses X-Ray technology to measure fill levels, detect internal contaminants, and assess foam levels with precision.
To decide on the best inspection system, consider how each method aligns with your production requirements.
Throughput: The inspection speed should match your production line's pace. FILTEC systems can inspect up to 2,400 cans per minute or 1,200 bottles per hour. Use vision systems for external checks and X-ray systems for internal assessments.
Container Material Compatibility:
For complete quality control, integrating vision and X-ray systems can be highly effective. FILTEC's INTELLECT platform simplifies this by combining multiple inspection points - both internal and external - into a single dashboard for monitoring and reporting.
Advantages of Combining Systems:
Effective container inspection requires a balance between checking the internal density and evaluating the external surface, considering factors like container materials, production speed, and quality goals. The INTELLECT platform brings these inspection processes together, providing a unified solution for quality control. This ensures product integrity and compliance with regulations in both beverage and pharmaceutical production lines. By aligning inspection methods with production demands, manufacturers can uphold top-tier container quality and prioritize consumer safety with integrated, real-time monitoring.