Process Control is
Key to Efficiency

Hitachi Vision System for Verifying Print Accuracy on the Canning Line

At a glance

About Okocim Brewery

Okocim Brewery has over 170 years of brewing heritage. It is not only the largest brewery in the Carlsberg Group in Poland but also one of the largest and most modern Carlsberg Breweries in Europe. It is renowned for the highest quality beer it brews.

Challenges

Incorrectly marked products were caused by:

Complaints

Resulting from high line speeds, making it difficult for staff to control print quality. Incorrectly marked goods let to complaints, generating high logistical costs and negatively impacting the company’s image.

Demanding Production Environment

The linear speed of conveyors reaching 105 meters per minute required the system to capture and analyze prints rapidly to reject incorrectly marked products in time.

Implementation

Initially, a series of speed tests were conducted on the system due to the high line performance (105 m/min, and 60,000 cans/h).

It was also necessary to select the appropriate lighting device for the concave bottom of aluminum cans to allow 100% print reading by the camera.

The next step was to choose a printer that would enable precise marking at high speeds in two lines. The choice fell on a model with two 65µ nozzles, allowing for larger dots for better print visibility.

After installing the vision system, it was connected to the printer so the operator could input print content into one device. Additionally, the system was equipped with remote access functions, allowing for remote parameter monitoring and device servicing.

Results

By implementing the Hitachi vision system, the client was able to eliminate problems with incorrectly marked cans. Reducing returns and lowering complaint handling costs contributed to increased operational efficiency and strengthened the company’s image as a producer committed to the highest quality products.

The success of the project led the Management to decide to purchase and implement another vision system for a similar production line. Further, in cooperation with the plant’s automation department, conveyors were stabilized using chemical anchors, a rejector for incorrectly labelled cans was installed, and a tank with a cushioning jacket was added for rejection.

The final stage of the project was installing the system at the plant, calibrating it with the rejector, and providing technical training for operating the device.

Benefits for the client

Eliminating print errors improved the quality of the client’s products, significantly impacting the company’s positive image among customers and discount chains.
The decrease in returns due to incorrectly marked cans reduced production costs.
Increased operational efficiency improved the company’s ability to perform optimally and improved results while generating savings.
Remote access to the system allowed for checking parameters and errors, reducing the number of failures and thereby improving work efficiency.

„The professionalism and commitment of Hitmark’s employees make us wholeheartedly recommend both their products and service. Thanks to working with Hitmark, our production has become more efficient and reliable“

Marcin Bedlin, Director of Okocim Brewery