Systems We've Integrated
Real inspection systems we've engineered, built, and deployed — from facility assessment to production-floor commissioning.
Nova Sorters
Industrial Color Sorting System — Complete Integration
The Challenge
Nova Sorters needed a complete inspection automation system for their industrial color sorting machines — capable of processing up to 6 tons of material per hour across 3 product lines, with sub-0.1mm foreign object detection and real-time color classification.
The system needed to handle the full pipeline: high-speed image acquisition, AI-driven sorting decisions, and physical reject actuation — all running on-premise with zero cloud dependency and industrial-grade reliability.
What We Integrated
Line-scan cameras
High-speed acquisition across 3 product lines with synchronized triggering
Custom LED bar lighting
Uniform illumination arrays designed for accurate color classification at speed
Backlight panels
High-intensity diffused panels for foreign object detection and shape-based rejection
AI deep learning models
Real-time color classification, defect detection, and foreign object identification
On-device edge compute
On-premise GPU inference — no cloud dependency, sub-millisecond latency
Sub-millisecond reject gates
Pneumatic reject mechanisms with precise timing synchronized to line speed
High-speed conveyors
Integrated material handling with encoder-based speed synchronization
Real-time analytics dashboard
Production metrics, defect rates, and trend visualization for operators and managers
Pipeline
System Architecture
End-to-end inspection flow — from product entering the conveyor to cloud-visible decision — in under 10 ms per frame.
Results
Integration Timeline
Discovery & Requirements
6 weeksFacility visit, defect characterization, throughput analysis
System Design
20 weeksCamera/optics selection, lighting design, architecture specification
Build & AI Training
16 weeksHardware assembly, model development, lab validation
Install & Commission
20 weeksOn-site installation, PLC integration, production-speed validation
Ongoing Support
ContinuousModel retraining, OTA updates, system monitoring
Industries We're Expanding Into
We're applying the same full-stack inspection approach to new verticals. These are the industries we're building toward next.
Coming SoonPharma & Packaging
Pharmaceutical Blister Pack Inspection
Complete inline inspection system for blister pack verification — tablet presence, seal integrity, and label compliance with 21 CFR Part 11.
Coming SoonAutomotive
Automotive Surface Defect Detection
Multi-camera surface inspection system for machined automotive components — integrated with production line PLC and MES.
Coming SoonRobotics & Automation
Vision-Guided Robotic Bin Picking
3D vision system integrated with robotic arm for random bin picking of mixed parts — AI-driven pose estimation with collision-free path planning.
Have an Inspection Challenge?
Let's discuss how a complete, integrated inspection system can solve it.