OneBoxVision Blog

Specifying your plastic film inspection system

Plastic producer need to consider how to deploy inspection as an infrastructure. This article highlights the importance of planning and deploying a vision system infrastructure.

Plastic inspection systems today are applied to inspect a variety of plastic applications including:

  • Plastic packaging.
  • Medical film.
  • Blown film.
  • Flexible packaging film.
  • Cast film.
  • Window film.
  • Battery film.
  • PCB material.
  • Polarizer film.

Defect detection is key to the success of your vision system, but so also is classification so that information can be used to optimize the production process.

Plastic inspection defects detected

  • Bubbles
  • Dent detection
  • Dark Spots
  • Water Stains
  • Gels
  • Fish Eyes
  • Fractured
  • Melts
  • Wrinkles.
  • Splices
  • Scratches
  • Coating voids
  • Insects
  • Coating voids
  • Streaks
  • Holes

Gel counting is a common requirement for plastic film inspection.

      A gel counting user interface   Gel counting results guide

The image above is an example from OneBoxVision 

It's a must to include the capability to count gels and use that information to improve your extrusion process and also the quality of raw substrate used. Classes of defects may be defined and parameters for each type decided. Those classes can then be added to a density analysis to count occurrences in a fixed area or a moving window for web and sheet inspection. If the limit is exceeded, an application alarm can be triggered. Application alarms can then be connected to physical I/0 outputs to drive field devices.



You need to be able to inspect on extruders, slitters and laminators

Your vision system supplier should be able to support a network of vision solutions that  can be installed on slitters, extruders, and laminators. 

Be sure to make it easy to use for operators 

The software must be designed for ease of use. Key features should include:

  • Live visual display of material.
  • Defects displayed and stored.
  • Full video of production to disk.
  • Recipes different products.
  • Alarms.


The image above is an example from OneBoxVision 

Quality management and waste removal

Each production run should be archived and ready to import into your existing historian. The quality department must be able to review production and also supports automated waste removal in downstream processes. There should be the ability to 

  1. Display a graphical map of complete production run.
  2. Click and display all defect images.
  3. Filter capability to display types or class of defects.
  4. Export to excel for custom reports.
  5. Rewind module used with I/O to automate waste control.


The key to improving your process with vision systems is to build inspection solutions that work for the complete factory. No longer should a plastics factory consider purchasing a single solution for an isolated customer claim. Modern process operations should now look at building a comprehensive plastics inspection solution built around a vision system infrastructure. Make sure to choose a vendor that can not only inspect your plastic film but also support smart converting. Download our whitepaper to learn more.

Download planning a vision system network

Topics: Surface inspection systems Building and buying vision systems Plastic film inspection Building vision networks