Read the barcode on every pack
A barcode tied to the product running is the fastest check. A pack whose code reads but does not match is rejected, the same as a pack with no read.
Guides
Preventing wrong-label and mixed-product escapes
A wrong label is one of the most common causes of packaging recalls, and it almost always starts at a changeover.
Where do wrong labels come from?
Leftover labels from the last run, a roll from the wrong lot, a mixed case of cartons, or an artwork change that did not reach every station. Line clearance catches most of them. A camera on every pack catches the ones people miss.
Which checks stop a wrong label?
Match the artwork
Comparing the label image against the approved artwork catches wrong flavors, wrong languages and old versions that share a barcode.
Read key text
Character recognition on the product name, strength or allergen line adds a check that does not depend on the barcode alone.
Check the insert and the case
Leaflets, inserts and shipping cases get mixed too. A code read at each level ties the pack to the case.
Confirm the reject
A reject that does not happen is an escape. Confirm each rejected pack reached the bin, and stop the line if it did not.
Tie it to changeover
Load the expected product from the recipe or work order at changeover, so the station checks the new product from the first pack.
Test the station with deliberately wrong labels at every changeover, not just at startup.
FAQ
Common questions
QIs a barcode check enough?
It catches most errors, but two versions of artwork can share one barcode. An image or text check closes that gap.
QWhere should the camera go?
Right after the labeler, so a bad roll is caught within a few packs, with a reject before the case packer.
QCan it handle many products on one line?
Yes. Each product's expected codes and artwork are stored in a recipe, selected at changeover.
QDoes this replace line clearance?
No. It backs it up. Line clearance stops most mix-ups and the camera catches what gets past.