Project Overview
We developed a high-speed code reading and serialization traceability solution for the production lines of one of Turkey's leading food manufacturers exporting chocolates, wafers, crackers, and biscuits under the mandatory Chestny Znak (Russian DataMatrix) regulatory framework.
Deployed across 5 distinct manufacturing facilities in Turkey, the project involved scanning 2D DataMatrix codes on high-speed lines reaching 300–350 products per minute, reporting them to the central track-and-trace repository, automatically sorting non-compliant items, and routing valid products into aggregation and case packing.
High-Speed Precision & Project Challenges
With extremely rapid line velocity, each product required comprehensive verification in milliseconds. Our solution scans products in under 50 milliseconds, decodes the Chestny Znak DataMatrix code, and relays the payload to the factory database.
Key hurdles included multi-SKU variations running on identical lines and severe optical reflections caused by glossy metallized packaging films. High production rates demanded that optical decoding and AI verification occur simultaneously with zero cycle time penalty.
The ANAVIS Solution: Integrated AI Vision & Smart Optics
To overcome these challenges, we deployed smart industrial code readers equipped with specialized optical illumination and deep-learning decoding algorithms:
- Red Illumination & Polarizing Filters: Completely suppresses glare on shiny metallic foil and glossy wrappers.
- AI-Powered Decoding Algorithms: Reads distorted, curved, or low-contrast codes with maximum read rates.
- Liquid Lens Autofocus: Automatically adjusts optical focus on-the-fly during product changeovers without mechanical intervention.
- Embedded All-In-One Hardware: Operates autonomously without external PCs, external lenses, or bulky external lamps.
- Multi-Protocol Industrial Interfacing: Sends high-speed I/O reject triggers over PROFINET to the line PLC while streaming image logs via FTP for regulatory audit trails.
How the System Works
- 01 High-Speed Feeding: Products travel through the inspection tunnel at speeds up to 350 items/minute.
- 02 Sub-50ms Optical Acquisition: The autofocus vision sensor captures the 2D code in under 50 ms.
- 03 AI Syntax Validation: The crypto-tail and DataMatrix quality parameters are validated.
- 04 High-Speed Rejection: Uncoded or illegible products are immediately diverted by pneumatic diverters.
- 05 PROFINET & FTP Sync: Valid code data is relayed to the PLC while product images are archived over FTP.
- 06 Aggregation & Packaging: Verified packs move smoothly into carton and pallet aggregation.
