Individual Vision Tools or Fully Integrated Systems? A Strategic Comparison

Reducing Complexity, Increasing Efficiency

Demands on visual inspection in industrial manufacturing are constantly rising – driven by tighter regulations, increasing quality expectations, and the need for traceability. At the same time, there is pressure to design processes that are efficient, space-saving, and flexible. In this context, production leaders must ask: How can an optical inspection system be designed to meet today’s requirements and remain scalable tomorrow?

This article explores three technological approaches – from basic vision sensors to modular vision systems to fully integrated solutions – and shows why integration level and interface design are becoming critical success factors.

Three Technological Approaches Compared – Beyond the Surface

Choosing the right system is not just a technical decision. It carries strategic implications for training effort, line availability, scalability, and ultimately the total cost of ownership.

Feature	Vision Sensors	Vision Systems	Fully Integrated Vision Systems (Wipotec)
Inspection Complexity	Simple: go/no-go	Advanced: configurable	Fully automated with process integration
Customization	Limited	Flexible, but complex integration	Fully adaptable with automated parameter control
Integration Effort	Minimal	High, requires third-party systems	Seamless, single interface
User Experience	Basic functionality	Multiple software interfaces	Intuitive operation, central control
Maintenance & Support	Limited	Multiple support contacts	One-stop service with rapid response

Modular or Integrated? Why Systems Must Go Beyond Components

Traditional vision systems are often assembled from standalone components provided by different vendors. While this modularity appears flexible at first glance, it can lead to:

Software interface discontinuities
High commissioning efforts
Increased error susceptibility during product changes
Complex support chains in case of malfunctions

In a time of limited resources and growing skills shortages, these factors can become bottlenecks. A system that functions as a closed ecosystem offers clear strategic benefits.

Integrated Vision Inspection as an Enabler of Digital Production

Fully integrated vision systems are more than inspection tools. They are data-leading units that seamlessly integrate into MES and ERP environments. They manage product transport, lighting, print image control, checkweighing, and ejection – all on a minimal footprint.

Technological Features with Foresight

OPC UA synchronization for end-to-end communication
Automatic product parameters minimize error sources
Unified data source for camera control and print layout

Operational Advantages for Decision Makers

Reduction of system variety on the line
Centralized, intuitive interface minimizes training
Improved line availability through integrated service and control

Industry Insights – Learning from Best Practices

BASF uses fully integrated inspection solutions in its crop protection production lines to manage fast product changes in a controlled and documented manner.

Block House demonstrates how integrated systems maintain performance even in cool environments with frequent changeovers.

Meguin applies systems with several fully integrated vision tools to check the cap, read Track & Trace codes, inspect labels and imprints.

What unites all these examples: Integration was less about technology – and more about adopting a holistic approach to quality control.

Conclusion

Integration is a Strategic Lever for Efficiency and Scalability

For those who view quality as a process – not just as final control – integrated systems are indispensable. They streamline operations, align processes, and provide a consistent data foundation for production and quality assurance.

This turns optical inspection from a reactive task into a strategic instrument for companies aiming to scale, digitize, and future-proof their operations.