Why Automated Product Inspection Needs a Digital Makeover

Updated October 2024

In the fast-paced manufacturing world, accuracy and efficiency has never been more important. Companies are under pressure to deliver high-quality products while minimizing waste and reducing costs. Traditional product inspection methods, which rely heavily on visible barcodes and manual processes, are increasingly falling short of these demands. Enter Digimarc Automate—a solution that uses digital watermarking technology to modernize digital product inspection.

The Limitations of Traditional Product Codes

Traditional product codes, such as barcodes and QR codes, have been the backbone of product tracking and inspection for decades. However, they come with several limitations:

1. Visibility Issues: Traditional codes need to be visible to be scanned. This can be a drawback in environments where products are damaged, or labels are obscured.
2. Aesthetic Compromise: Visible codes can mar the aesthetic appeal of packaging, particularly on irregularly shaped products, as well as on small items with limited space.
3. Orientation Sensitivity: These codes often need to be aligned correctly with the scanner, which can be challenging in high-speed production lines.

The Power of Digital Watermarks

Digimarc Automate addresses these limitations by embedding imperceptible digital watermarks across packaging and products. For packaging formats, such as cylindrical, irregular-shaped items and thin flexibles, digital watermarks excel over small visible codes, ensuring reliable scanning regardless of orientation on production lines. 

Digital watermarks can also be read by standard vision systems, providing several key advantages. Since watermarks are imperceptible to the human eye, they don’t affect the product's appearance, preserving brand integrity and packaging design. Compared to traditional codes, digital watermarks ensure consistent, reliable scanning, even in harsh industrial environments. Finally, digital watermarks can be scanned from any orientation, which significantly improves scanning efficiency and accuracy on fast-moving production lines.

Enhancing Efficiency and Reducing Waste

Traditional inspection methods, particularly those relying on manual labor, are prone to errors. Studies have shown that manual inspections can result in significant costs due to product recall, not to mention the safety risks associated with mislabeled products. 

“Studies consistently show that manual inspections are prone to errors, leading to substantial costs associated with product recalls and rework,” said Ken Sickles, Digimarc’s Chief Product Officer. “Beyond the cost, consumer safety is a top priority for brands and retailers. Labeling mix-ups have caused food products to be shipped without proper disclosure of ingredients. In the case of allergens like peanuts, milk, or gluten, this can be life-threatening. We are excited to offer a solution.”

The Future of Industrial Automation

The partnership between Digimarc and OMRON further amplifies the capabilities of Digimarc Automate by uniting cutting-edge digital watermarking with industry-leading machine vision technology. This combination not only improves product inspection but also transforms production processes across industries. 

In a time where precision, efficiency, and sustainability are paramount, traditional product inspection methods are no longer sufficient. Digimarc Automate overcomes the limitations of traditional codes, enhances operational efficiency, and meets evolving consumer demands.