Variable data can be applied to a product or its packaging quickly and cost-effectively using dot-matrix lettering. With the dot-print tool of the CIVCore image analysis software from METTLER-TOLEDO CI-Vision, it is possible to automatically read and verify dot-matrix fonts even at high speeds.
Many manufacturing and packaging companies rely on the continuous inkjet process for high belt speeds. However, previous OCR algorithms often reach their limits when it comes to reading the applied information such as BBD, production date or batch number.
Due to the degraded character strings and different packaging properties such as curved or transparent surfaces, it was not possible in many cases until now, Automated reading of dot-matrix fonts with camera systems. The CIVCore image analysis software integrated in the METTLER-TOLEDO Dot-Print-Tool overcomes this technological hurdle. Through a Predefined dot matrix for each character dot-matrix fonts can be independent of the packaging surface Automated read in and verify. Depending on the code applied, this opens up a wide range of new possibilities for manufacturers and packagers in terms of logistics and quality assurance, regardless of the industry.
We have already reported on the new technology and its future potential applications. Reinhold van Ackeren, Head of Marketing & Product Management at METTLER-TOLEDO CI-Vision in Zwingenberg, in detail:
pj: Mr van Ackeren, dot-matrix fonts are widely used in the consumer goods industry. However, it has not yet been possible to read the fonts automatically. What is the actual reason for this?
Reinhold van Ackeren: In a nutshell: the existing technologies. Template-based OCR and Geometric OCR are the most common variants in the industry. However, both solutions require constant recording conditions in order to work reliably. With dot-matrix writing, the characters are interrupted and the printed information is often located on curved or transparent surfaces, such as bottle necks. These obstacles put conventional OCR processes in their place and manufacturers are often limited to manual, random visual inspections.
pj: And the dot-print tool makes reading possible despite the difficulties mentioned?
Reinhold van Ackeren: Exactly. The dot print tool is an integral part of our CIVCore image analysis software and is based on SureDotOCR technology from Matrox Imaging. The special feature here is that the operator stores the dot matrix for each individual character in the dot print tool from the outset. The character definitions can be obtained directly from the printer or created manually - this also applies to special characters and umlauts. The software also requires information on the dot size and the dimensions of the field in which the dot-matrix font is printed. With this information, the OCR algorithm can reliably identify the characters. The great strength of this process lies in the Parameterisation. The algorithm tolerates and recognises signs itself, due to the printing process or the packaging surface. tilted, distorted or incomplete are.
pj: That sounds like a major advance in the dot-matrix OCR process. What are the consequences of this technical innovation for manufacturing and packaging companies?
Reinhold van Ackeren: This opens up a whole range of new possibilities for manufacturers. On the one hand, there is dot-matrix lettering, which can be applied to the product or packaging quickly, cost-effectively and at very high belt speeds. On the other hand, we are now able to read and verify all variable information such as production date, best-before date or batch numbers applied in dot-matrix writing using existing printing systems - and therefore without any new investment in this area. This enables manufacturers to guarantee One hundred per cent control of every single product and raise their quality standards to a higher level.
And practice shows: The demand is there. Many retailers are asking their suppliers for a BRC-7 certification in accordance with the specifications of the British Retail Federation. Among other things, these include a one hundred per cent visual inspection of the product packaging and all applied information. With a combination of dot-matrix printer and dot-print tool, this can now be realised. Cost-effective in high-speed production realise.
pj: Does one hundred per cent control also mean fewer losses?
Reinhold van Ackeren: In any case. In practice, it is the exception rather than the rule that a poor-quality product makes it to the shelves, but time-consuming and expensive reworking in production are definitely an issue. Most defects are simply due to negligence. A classic mistake, for example, is that the employee responsible for a product change forgets to change the labelling system to the new batch number. A visual inspection system recognises this immediately and sounds the alarm before excessive resources are wasted. With the manual visual inspection that was common with dot-matrix fonts in the past, an error like this may only become apparent after thousands or tens of thousands of finished products have been produced. The waste of resources and the cost of repackaging the products are correspondingly high.
pj: Are the new possibilities also radiating into the area of „Industry 4.0“?
Reinhold van Ackeren: Of course, especially during product inspection, comprehensive quality data provides valuable information with regard to Performance and predictive maintenance. With our dot-print tool, this now also works with dot-matrix labelling. The CIVCore software continuously stores data on the quality of the labelling and, if required, merges it with other product inspection data, such as from checkweighers, X-ray inspections or metal detectors, using our ProdX software. CIVCore also recognises Negative trends. If, for example, the nozzles of the printer become increasingly clogged, this affects the shape and composition of the individual dot matrix dots. The image analysis software immediately alerts the line manager to this situation. The line manager can then service and clean the affected printer. How manufacturers work Counteracting errors, before they arise.
pj: How quickly do you think the industry will adapt the new OCR technology?
Reinhold van Ackeren: Extremely fast, it is already being used in some areas. As mentioned, dot-matrix fonts are widely used in many sectors, for example in the food and cosmetics industries. Manufacturers who already own dot-matrix printers can expand their line with little effort. All you need is a camera and the image analysis software. The ratio of investment to benefit is extremely good here. With relatively little capital investment, manufacturers receive lines on which they can check dot-matrix lettering fully automatically and for every product. Added to this are the aforementioned advantages in terms of quality assurance. Many manufacturers have recognised this and are open to investment in this area.
