Automated Package & Label Defect Inspection on High- Speed Conveyor Lines

A high-volume consumer packaged goods (CPG) facility producing 120,000 packaged food items daily across 6 high-speed conveyor lines.

annual retailer chargeback penalties and product return costs: $450,000annual retailer chargeback penalties and product return costs

How the work runs

The pressure that made this worth automating, the steps the system runs, and what came out the other side.

Pressure & Trigger Points

Packaging defects (missing cap seals, crushed boxes, misaligned barcode labels) slipped past human visual inspectors at line speeds of 300 units/minute.
Defective products reached retail customer shelves, causing expensive retailer chargeback fines and product returns.
Installing proprietary inline vision inspection hardware required stopping production lines for weeks.

The run · 5 operational steps

Click any step to inspect telemetry signals, model reasoning, and governance gates.

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Arjuna ingests high-frame-rate video feeds from standard industrial cameras positioned over existing conveyor lines.

Input Signal:

Real-time operational telemetry & queue

Reasoning Pattern:

MCP grounded vector inference

Governance Gate:

Policy constrained with audit write-back

Verified Business Outcomes

Defective package escapes to retail customers reduced to zero.
Saved $450,000 in annual retailer chargeback penalties and product return costs.
Retrofit installation completed over a single weekend without disrupting production schedules.

Capabilities this relies on