The customer is a professional enterprise engaged in the packaging industry, with one of its production lines dedicated to bottle cap manufacturing. During the bottle cap production process, ensuring each cap is equipped with the correct gasket is of crucial importance. To effectively reject unqualified bottle caps (those with missing gaskets or incorrectly oriented gaskets) on the production line, the customer needs to select a sensor that can accurately identify whether the gaskets in the bottle caps comply with specifications, thereby guaranteeing the uniformity and sealing performance of the bottle caps.

Detection Challenges

Complex Gasket Colors: Qualified gaskets are pure silver, while unqualified cases include gaskets with red logos and caps without gaskets. The customer has previously tested multiple sensors available on the market, but none could stably distinguish the subtle color difference between silver and red logos.

Response Speed Requirement: The high-speed production line requires the sensor to complete detection and feedback signals within milliseconds.

Working Condition Restrictions: The sensor must be installed at a distance of no less than 400mm, demanding equipment capable of long-distance detection.

Solution

After a detailed evaluation, the EB-W500 Series long-distance color sensor with white LED light source was recommended to the customer. Leveraging its high-precision color recognition and fast response capabilities, it enables fully automated sorting of gaskets for compliance:

Long-Distance Accurate Color Matching: The sensor supports a detection distance ranging from 50mm to 500mm, easily adapting to the 400mm installation distance. Its concentrated light spot and resistance to ambient light interference allow effective identification of the color difference between silver and red logos.

Stable Detection: The white LED wide-wavelength light source ensures precise color discrimination and filters out ambient light interference; anti-vibration function and background suppression guarantee stable detection performance.

High-Speed Response: Millisecond-level response matches the production line’s beat.

Implementation Method：The sensor is installed above the conveyor belt (at a distance ≥ 400mm). Qualified silver gaskets are allowed to pass through, while unqualified products (those with red logos or missing gaskets) trigger an air blow to reject them. The entire process is fully automated without manual intervention.

Core Product Advantages

Equipped with a white LED light source with a wide wavelength range, enabling stable detection of color or appearance differences.

Excellent anti-vibration performance and built-in background suppression function.

Capable of long-distance color detection.

Can store up to 9 color samples simultaneously.

Optional IO-LINK communication function.

Adjustable light spot.

Implementation Results

By deploying the EB-W500 Series color sensor, the customer’s production line has achieved fully automated and accurate sorting throughout the process:

✅ Quality Improvement: The rate of gasket missing or reverse installation issues has decreased, and the qualification rate of bottle cap sealing performance has significantly increased.

✅ Efficiency Optimization: The rejection action is seamlessly synchronized with the production rhythm, improving the production line speed and eliminating the need for manual re-inspection.

✅ Cost Control: The sensor operates stably for a long time with low maintenance frequency, reducing downtime losses and labor costs.