KHS integrates AI into its inspection technology

GERMANY – KHS, a German turnkey systems provider, has integrated AI into its Innocheck TSI closure inspection unit for tethered cap compliance.

Tethered caps have been mandatory for all nonreturnable polyethylene terephthalate bottles in the EU since last year.

This innovation addresses the growing variety of closure designs and the increasing demand for inspection technology.

According to the Dortmund-based company, the introduction of tethered caps has required bottle and beverage producers in the EU to adapt to ensure product quality and protection.

Additionally, the inspection process has been complicated by the growing number of bottle and cap design variants, as well as increasing line capacities.

The AI-based fault detection system for tethered caps uses patent-pending algorithms to analyse high-resolution images of bottle closures in real time, according to KHS.

The innovation features cameras that capture detailed visuals, which AI models evaluate, employing deep learning to adapt to new types of defects.

This AI inspection system enhances the accuracy as well as the efficiency of inspections.

The AI module is designed specifically for the Innocheck TSI cap inspector, offering compatibility with both new and existing machines.

In the future, KHS plans to extend AI applications to additional inspection technology equipment.

KHS labelling and inspection technology product support executive Nikita Wall emphasized, “Tethered caps were rarely used before the EU directive came into force. Conventional systems thus frequently reach the limits of their capacity where cap inspection is concerned.”

“Our customers make extremely high demands of quality assurance. In intensive field tests, our AI-based fault detector has proved that it fully meets these requirements.

“In the development team, we’re currently discussing which systems this would make sense for. AI solutions are only practical where the requirements are complex, and if they give our customers clear benefits.”

Last month, KHS Group set out to showcase its pioneering portfolio of technologies and services designed to meet the evolving demands of the global beverage industry at Drinktec 2025, from September 15-19, 2025.

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