Catching Defects Human Eyes Miss.
An AI-powered automated quality inspection system built for high-speed production lines. CapEye leverages custom computer vision software to detect product defects at 300+ units per minute — eliminating costly recalls, reducing waste, and protecting brand reputation through AI-driven automation.
The business problem and the software solution.
THE BUSINESS CHALLENGE
A leading bottling manufacturer was losing thousands of units per week to undetected seal defects. Human inspectors simply couldn't keep up with production speeds of 300+ bottles per minute, leading to defective products reaching customers and expensive recalls that cost the company over $500K annually. The existing manual inspection process was inconsistent, fatigued-dependent, and couldn't scale with increasing production demands. They needed bespoke AI software that could integrate directly into their conveyor systems without disrupting operations.
THE SOLUTION WE DELIVERED
We designed and deployed a custom AI software solution using deep learning-based computer vision models trained on 50,000+ defect images. Smart cameras installed directly on the production line inspect every single product at full speed, instantly flagging and rejecting defective items before they leave the factory. The system integrates with existing PLC controllers and SCADA systems, requiring zero hardware overhaul. Our cloud-connected dashboard provides real-time analytics on defect rates, production throughput, and model confidence scores. The full integration was completed in under 6 weeks without any production downtime.
How the project was planned, built, and launched.
Understanding the Line
Spent 2 weeks on the factory floor studying defect patterns, lighting conditions, and conveyor speeds to design the right solution.
Proof of Concept
Built a working camera prototype that detected seal defects in controlled conditions with 97% accuracy within 3 weeks.
Teaching the AI
Trained the detection model on 50,000+ images of good and defective seals until accuracy exceeded 99.9%.
Going Live
Installed the full system on 4 production lines with zero downtime. Operators were trained in a single afternoon.
Core capabilities delivered for the client.
FEATURES
Catches What Eyes Can't
AI-powered cameras detect microscopic defects that are invisible to human inspectors, even at high speed.
Runs at Full Production Speed
Inspects 300+ units per minute without slowing down your line - zero bottlenecks.
Zero False Alarms
Smart filtering means only real defects get flagged - no wasted product, no unnecessary stoppages.
Works With Your Existing Equipment
Plugs directly into your current production line hardware - no expensive overhauls needed.
We went from losing thousands of defective bottles a week to catching virtually every single one. CapEye paid for itself within the first two months.
What the client achieved after launch.
Within 60 days of deployment, the client saw a complete elimination of customer-reported seal defects. The $500K annual loss from recalls dropped to zero.
If you need a custom software platform, AI implementation, cloud engineering, or product modernization, we can review your requirements and recommend the right path forward.
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