From supply chain disruptions to labour shortages and the diversification of consumer demand, the UK’s manufacturers have faced a variety of challenges over recent years. Many have turned to automation and machine vision technologies in the aim of enhancing product quality, efficiency, and compliance. Enabling the monitoring, analysis, and improvement of product quality in real-time, such technologies effectively minimise the risk of product issues. Over 70% of UK manufacturers have adopted or plan to adopt machine vision for the realisation of such benefits in 2026, according to the Industrial Vision Association. Manufacturers across such sectors as food and beverage, pharmaceuticals, and automotive are the main drivers, with a focus on fulfilling strict regulations and customer expectations.

We’ll explore the transformative impacts of machine vision on quality control in packaging here.

Why Machine Vision Is Becoming a Manufacturing Essential

There’s growing pressure to meet strict product and regulatory requirements, while also controlling costs, in the UK’s manufacturing sector. Time-consuming and error-prone manual inspection processes are proving insufficient in meeting such demands. However, there’s a positive transformation in the integration of machine vision systems, allowing for the rapid identification of product issues that might otherwise go unnoticed. Such systems can scan packaging and labels in the blink of an eye, reliably detecting the smallest of defects and imperfections. This is particularly important in sectors such as food and drink, where there’s a focus on consumer protection and the preservation of brand reputations.

How Machine Vision Technology Works

Machine vision systems are typically comprised of high-resolution cameras, lighting systems, and processing units for the capture of items as they pass along the line. Such items move along on conveyors, with images or videos captured at rapid intervals. The visuals are then analysed with advanced software for the detection of deviations in colour, texture, dimensions, and positioning.

2D vision systems allow for surface-level inspection, such as the checking of missing print or label misalignment on packaged products.

3D systems can be used to check the consistency of product formats, particularly important for baked goods and machined parts. 

Infrared and thermal imaging systems allow for temperature-sensitive checks, as with the verification of heat-sealed packages.

Upon the detection of faults, such automated systems automatically stop the production line, with faulty products being rejected via shoots or secondary conveyor lines. Real-time alerts are sent to the operators for investigation, with the complete process taking place in milliseconds and allowing continuous monitoring.

Real-world Packaging Applications

From the identification of surface scratches to the validation of fill levels and verification of barcodes, there are numerous real-world examples of machine vision in the packaging sector. The July-August 2025 edition of Machinery Update focused on the MPAC Group’s acquisition of SIGA Vision, with the use of AI for the checking of pallet integrity, identification of contamination, and compliance across fast-moving supply chains (page 46). Reference was also made to the MPAC Replay diagnostic tool, which automatically captures and stores footage of any machine stoppages for swift diagnosis and resolution. And the September/October 2025 edition highlighted the integration of the Sony IMX900 Sensor into compact cameras for the delivery of pin-sharp images, even in confined locations (page 19).

Other machine vision applications include:

• Checking of packaging against tolerance specifications (width, height, and shape consistency)
• Verification of label accuracy and placement
• Confirmation of clean, secure, and contaminant-free seals

Clear Business Benefits

Packaged product manufacturers stand to see a range of benefits in the adoption of machine vision systems for such purposes.

Improved Efficiency and Accuracy

As mentioned, the automation of a previously time-consuming manual process results in enhanced efficiency and accuracy. Such systems have the capacity to rapidly scan large quantities of products, with any issues being identified in real-time and production stopped or altered accordingly. This greatly reduces the risk of faulty products going into distribution, boosting customer satisfaction and preventing the damage of company reputation.

Enhanced Safety and Compliance

In effectively minimising the risks of product defects and package mislabelling, machine vision systems make for improved consumer safety. Camera inspection systems also fulfil the demand for digital traceability, collecting visual data and reports for improved regulatory compliance. Manufacturers can have greater confidence in meeting the quality standards set out in ISO, BRCGS, and pharmaceutical regulations.

Process Cost Savings and Workforce Health

In automating previously manual inspection processes, manufacturers no longer have to worry about the impacts of fatigue or boredom. Machine vision systems can run for as long as needed with minimal human supervision, freeing up workers to focus on higher-level tasks. The reliable detection of defects and non-conformities also means that manufacturers can have more confidence in distributing high-quality goods. Benefits such as reduced spoilage, material cost savings, and sustainability support are particularly relevant across industries like food and pharma.

The Role of AI in Next-Generation Machine Vision

As with other aspects of manufacturing and production, the integration of AI with machine vision systems is becoming increasingly common. Such systems have the capacity to analyse past production data for the identification of fault patterns and emerging trends. This continuous learning allows for real-time adaptation, with the adjustment of packaging manufacturing processes for greater accuracy and fewer false rejects. Drawing on predictive analytics, manufacturers can pre-schedule maintenance for the reduced risk of breakdowns and enhanced overall equipment effectiveness.

Such benefits can be realised with Ishida’s Sentinel 5.0, with advanced data analysis providing unique insights into production performance. Learning normal behaviour and detecting deviations and long-term trends, this production monitoring system enables the transition from reactive quality control to proactive process improvement. It is important to remember that AI does not replace poorly specified equipment. It is vital that an experience integrator specifies a vision system. AI then can enhance and expand on the capabilities of a system.

Adoption Across UK Manufacturing

Given such wide-ranging benefits, it’s not surprising that there’s an increased focus on machine vision investment across such sectors as food, beverages, and pharmaceuticals. The UK’s vision market is expected to grow at a rapid rate, with analysts recognising expanding automation and quality-control as the main driving factors. And the technology isn’t limited to large manufacturers, with affordable modular systems being accessible to SME’s seeking productivity and reliability gains.

Still, there are challenges to be overcome, with the increased adoption of machine vision depending on a strong technical infrastructure and the support of qualified personnel. Each production process has specific demands, with the regular maintenance and calibration of machine systems needed for optimum performance. However, there’s no denying the quality improvement that can be achieved through the automation of product inspection.

Supporting The Vision

As the leading trade association for automation suppliers and technology end users, Automate UK has a key role in promoting awareness and adoption of machine vision systems. We achieve this in partnership with our members, making the widest range of advanced inspection technologies available through the product finder. The latest innovations are also showcased at industry events, with Automation UK 2027 promising a fantastic line-up of vision-focused exhibitors. With machine vision enabling the real-time enhancement of quality, there’s every reason to explore the partnerships and integration support available from Automate UK.