In-Sight 3900 Series
In-Sight 3900 is a high-speed AI machine vision system built for high-throughput production lines, with powerful computing and embedded AI for processing high-resolution images and advanced inspections.
Automate cap and fill detection without slowing down your production line
With hundreds of liquid containers moving rapidly down production lines, accurate volume measurement is critical. It safeguards product quality, brand reputation, and customer trust. From juice and soup to hand soap and saline solution, every pouch, bottle, jar, or vial must meet strict fill level standards.
Consumers expect consistency, and any deviation is unacceptable. But fast-moving lines leave little room for error – overfills, underfills, and false positives can cause spillage, waste, and costly downstream issues.
As tolerances tighten and automation demands rise, manufacturers need reliability, efficiency, and confidence in their process. Cognex machine vision delivers exactly that, enabling precise, repeatable fill level verification before sealing or shipping – catching problems early, reducing waste, and ensuring consistent quality.
Improve product quality and reduce waste in fill level inspections
Fill level inspection faces many challenges: transparent or reflective packaging, bubbles, and foamy liquids can all make accurate detection difficult. With narrow tolerances, any deviation can lead to products being scrapped or reworked, adding cost and waste.
Human inspectors are prone to fatigue and errors that reduce consistency, making it extremely difficult to detect fill issues at line speeds of hundreds of parts per minute or in areas with limited visibility. Even traditional machine vision systems struggle with these complexities, leading to false rejects or missed defects.
Cognex 2D and 3D vision systems enhance this process by effortlessly handling the unique challenges posed by diverse products and packaging:
- Colored liquids: Variations in color and opacity affect how light passes through or reflects off the contents.
- Bottle materials: Clear glass, tinted glass, and opaque plastics require specialized imaging for visibility.
- Container shapes: Tall, narrow, or contoured packaging makes fill-line detection difficult due to angles and reflections.
With Cognex vision systems and AI, manufacturers get speed, precision, and adaptability for automated fill level inspection across industries:
- Consumer packaged goods (CPG): Make sure bottles, jars, and pouches are filled to spec, and verify seals to prevent leaks, spills, contamination, and tampering – reducing waste, protecting margins, and supporting label and regulatory requirements.
- Food and beverage: Ensure consistent fill levels in drinks, condiments, and dairy products to maintain quality and consumer satisfaction, even across high-speed production lines.
- Pharmaceuticals: Accurately measure fill levels in pharmaceutical products such as oral antibiotics, nutritional supplements, and vials, while supporting compliance with strict industry and global regulatory standards.
Trusted fill level solutions for demanding industries
With Cognex machine vision, you can have high-speed production without sacrificing quality in automated fill level inspections. Our solutions improve the performance of filling systems for both manufacturers and OEMs, delivering unmatched speed, accuracy, and simplicity for in-line fill level measurement:
- AI-powered technology adapts in real time to packaging variations with minimal training or reprogramming, catching defects early and minimizing rejects.
- 2D vision systems detect underfills and overfills by measuring pixel density, triggering automatic kick-outs to reduce product waste.
- 3D area scan cameras capture high-resolution images in 200 milliseconds or less, enabling full-volume inspection even on challenging containers.
- Vision sensors mount easily to conveyors and deliver pass/fail inspections in real time with no programming needed.
Whether you’re a beverage bottler or consumer goods manufacturer, the benefits of automated fill inspection are clear:
- Ensure compliance with industry regulations
- Increase line efficiency and reduce manual labor
- Protect your brand reputation by delivering consistent product quality
Along with Cognex support when you need it – from a global network of experts to on-demand resources – our solutions enable real-time fill level inspection and fast cycle times, even in the most dynamic, high-speed environments.