X-ray scanner for complete integration into plastic cup form, fill and seal machines

The SC-I sets new standards for inline quality control in form-fill-seal production. Fully integrated into filling machines, this compact X-ray scanner inspects sealed thermoformed cups with unmatched accuracy—detecting foreign bodies and monitoring fill levels before products leave the sterile zone. By scanning each cup individually in a single layer, the system minimizes false rejections and enhances productivity. With hygienic design, automated testing, and seamless system communication, the SC-I offers efficient, high-performance inspection in the smallest possible footprint.

The SC-I, also referred to as integration scanner, has been developed to scan solid, viscous and liquid products in thermoformed cups. This cutting-edge scanner is a unique and space-saving solution to detect foreign bodies and check fill levels in kind of thermoformed cups. Both tasks are performed with extreme high accuracies.

Overcoming End-of-Line inspection challenges with precision

In many modern filling lines, the sealed cups leave the system stacked in trays. Traditionally the X-ray inspection systems are installed after the filling system. This means the X-ray system are inspecting complete trays in serval layers. Usually the cups are not fixed in the trays. The overlapping of products means that end-of-line inspection systems are unable to provide optimal accuracy. This leads to an increased number of false-positive rejections. The unique SC-I solution takes a different approach to overcome these limitations.

Advantages:

Smallest footprint
Fully integrated into the filling machine
Highest accuracy in foreign body detection
Highest accuracy in fill level control
Best false-positive reject rate
Highest productivity
Easy operation via the filling system
Rejection of individual cups
Filler Feedback
Best in class TCO

The X-ray scanner for integration into filling lines

X-ray operating principle of the integratable scanner

Integration and lnspection

The SC-I is completely integrated into the filling line, mechanical, electrical and in the communication. The scanner is mounted downstream of the sealing station, just outside of the sterile section of the filling line. This is to ensure that all quality control criteria are still met by only scanning sealed products. Always a single layer of cups are fed through the scanner. The highperformance VioX camera and the X-ray tube are moved across the cups, perpendicular to their transport direction. As with all Wipotec X-ray inspection systems, the result is a pin sharp X-ray picture. The UXS image processing identifies the individual product compartments and detects foreign bodies and filling levels. The pictures of the rejected products are stored and archived. Each picture is easily identifiable with a timestamp or 2D codes, cup number and reason for rejection. All statistics can be processed and stored with the optional Comscale software on a server. After inspection, the SC-I transmits the individual numbers of the compartments and the corresponding scanning results to the filling machine via Ethernet. The filling machine uses this information to remove the affected cup from production.

The advantages of the system at a glance

Easy operation

The complete integration into the filling system includes an exchange of signals to communicate system status information. These signals include product changeover, start, stop and line synchronization. The whole line is therefore controlled from the display of the filling machine. Besides that, the scanner can be equipped with an RFID reader, to use employer badges to login to the authorized access level.

For highest hygiene requirements – inline cleaning is possible

The entire scanner is made of stainless steel and can be cleaned inline. The radiation protection hatches can be brought independently into the service position by means of servomotors. This allows an efficient cleaning of the scanner.

For verified safety – automated performance checks

The scanner can be equipped with an automatic test function, specifically developed for this solution, that moves a test object into the scanning area. These performance checks can either be triggered manually or after an adjustable period of time. This test function ensures that the performance checks, required by quality standards, can be carried out easily.

Radiation protection

The access panels in the filling line, which are required for radiation protection, are equipped with safety switches. As the scanner is fully integrated into the filling line, any open access panels will immediately switch off the X-ray source. Self monitoring signal lamps on both sides of the scanner indicates that the system generating X-rays.

For easy maintenance – the trolley

To facilitate all maintenance tasks, the SC-I is mounted an a specially designed trolley. The whole scanner can be easily pulled out of the filling line so that the X-ray system is accessible from all sides.