The latest news, trends, analysis, interviews and podcasts from the global food and beverage industry

What if routine quality checks could do more than just ensure compliance? Stefan Welker at Industrial Physics explores how modernising inspection processes with data-driven technologies and automation can transform packaging operations, reduce waste, strengthen brand trust and create tangible competitive advantages that drive long-term growth.

Reframing the traditional process of quality control has the potential to critically transform the way food and drink packagers conduct operations.

From reducing waste and unplanned downtime, to enhancing brand trust and customer satisfaction, modernising quality control processes offers a pathway to market differentiation and long-term growth: enabling manufacturers to gain efficiencies and deliver measurable value beyond pure compliance.

Deeper insights

When embedded into the core of packaging operations, quality control becomes a source of insight, rather than a resource-heavy requirement. To utilise quality control as a driver of performance, rather than a reactive safeguard, manufacturers must embrace data-driven technologies, automation and real-time monitoring tools.

Advancements in technology now offer information and control throughout each stage – whether containers are aluminium cans, plastic trays or flexible pouches – allowing for early intervention when any defects are spotted and building operational resilience.

By integrating advanced testing systems such as high-speed optical inspection, inline sensors and automated gauges, for instance, manufacturers can ensure consistency and accuracy in issue identification on the production line.

In beverage can manufacturing, automatic gun recognition and assignment during compound quality checks, or automatic recognition of the bodymaker ID for machine-related production quality recording are considered standard. These record key criteria in the process including trimmed can height, wall thickness distribution and bottom depth recording.

However, there are also opportunities in the area of three-piece cans to use automatic measuring devices to bring quality control to a more reliable level and thus achieve greater process control. A simple example is the recording of the bead profile analysis, which enables wear monitoring and the alignment of the rollers through increased can sampling. This directly leads to a higher axial load capacity of the can and can be used as a basis for possible downsizing developments to reduce material consumption.

The same applies, of course, to seam quality inspection. Automatic systems can now be automatically loaded with cans from the line, whereby the measurement results of the seam parameters can be directly assigned to a seamer head. This reduces the risk of seam defects and the time-consuming inspection of the entire seamer at regular maintenance intervals, while at the same time increasing product quality.

Advanced testing conditions allow manufacturers to maintain compliance and quality assurance, at the same time as reducing waste and improving resource utilisation.

Data-driven decisions

The use of Statistical Process Control (SPC) applications in combination with automatic test equipment facilitates stronger data collection, which can then be used to increase output, forecast maintenance requirements and reduce defects. By proactively identifying trends and anticipating upcoming failures or product defects, packaging manufacturers can create a more efficient production process. This is particularly desirable in the face of rising costs and where manufacturers are striving to achieve a targeted reduction in resources.

Advanced and automatic tools allow manufacturers to collect and monitor production data, spotting inconsistencies and addressing them at the earliest stage. For example, non-contact automated systems are available which measure coating thickness at the metal coil coating stage.

The incorporation of this technology facilitates full control of the process and allows coil coaters to ensure precise application of the required coating thickness but also distribution. For metal which will then be processed for can making, this ensures that the material is suitable and cans will not have to be destroyed once inspected if areas of the can have been under or overcoated, reducing the protective element afforded by the coating.

Competitively, the result of these faster, more effective automatic inspection processes is higher quality, which means improved reputation as trust is built right through the supply chain to the end customer.

Building trust

Consistent delivery of high-quality packaging builds brand trust. With the right test and measurement technology in place, businesses can obtain but also analyse the data required to fulfil this, meeting customer requirements reliably.

Automatic colour inspection, for instance, can reduce the volume of defective products manufactured. Colour is integral to consumer perception, and brand colours that are easily recognisable on the shelf have a positive influence on buying decisions. Automated colour inspection gauges provide that reassurance to can manufacturers by scanning multiple points on the packaging and comparing it to colour references and then confirming an exact match or rejection.

Maintaining customer trust through quality control can also be achieved via structural testing, a critical component which directly impacts consumer safety and brand integrity. Processes such as axial load and burst testing ensure stability and prevent collapse of packaging materials, which would damage brand reputation if the products made it to consumers.

Maintaining a high standard of quality control throughout the packaging process cultivates trust through the ability to sustain quality at scale. Manufacturers can demonstrate reliability, which boosts the confidence of brands and helps to build loyalty.

Quality control and sustainability

As the packaging industry’s impact on the environment comes under scrutiny for contributing to high levels of waste, sustainability has become an integral part of the production process but also the design of the package itself. Those who are packaging with sustainability at the forefront of their agenda are in prime position to appeal to consumers and be better prepared for regulation changes.

Sustainability provides a significant competitive advantage within food and beverage packaging by aligning environmental responsibility with product integrity. Packagers that prioritise sustainability are often supported by technology that focuses on minimising waste, whilst drawing on data that implements more transparent and traceable supply chains – enabling better oversight and control throughout the packaging process.

A mindset shift

The shift from quality control to process control in the packaging industry requires a change in mindset – away from viewing the product as a control point and toward strategic investment in safe and stable manufacturing processes. This inevitably leads to competitive advantages due to reduced resource consumption.

Through advanced technologies, data-driven insights and a culture of continuous improvement, food and beverage packaging manufacturers can improve performance across the board. In doing so, there is an opportunity to reduce costs, minimise risk, elevate sustainability profiles and enhance reputation to overcome competition.