Industrial machine vision for demanding inspection tasks

Machine vision solutions from a systems integrator – when off-the-shelf solutions aren’t enough

Machine vision makes quality visible – directly within the production process, in an automated and repeatable manner. It detects defects, checks features, reads codes, measures components and reliably documents inspection results during operation.

OCTUM develops and integrates machine vision systems for industrial inspection tasks. As a system integrator, we take into account not only the camera, optics, lighting and software, but also machine integration, interfaces, user interface design, data connectivity and long-term serviceability.

This results in image processing solutions that are tailored to the inspection task, the product, the equipment and the actual production conditions.

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Experienced in industrial image processing

OCTUM has been developing machine vision systems for demanding production environments since 1996. Our solutions are used worldwide – wherever products, components, packaging or codes need to be reliably inspected in-line.

 

30 years of experience

in industrial image processing, optical quality inspection and machine vision. 

 

6.000+ installed systems

worldwide in production-critical applications.

 

In-house software solutions

for flexible, scalable and regulated inspection processes. 

 

System integration

in machinery, plant and existing production lines. 

 

Regulated applications

for production environments with high standards regarding documentation, traceability and validability.

 

Long-term support

from commissioning and training to after-sales service and adaptation to new formats or test criteria.

 

What is industrial image processing?

Industrial image processing, also known as machine vision, uses cameras, optics, lighting and software to automatically inspect products, components or packaging. The systems capture images directly during the production process and evaluate them against defined criteria.

Typical tasks include detecting defects, checking for presence and completeness, verifying orientation and position, measuring features, and reading and verifying codes or plain text.

Compared to manual visual inspection, industrial image processing is objective, repeatable and provides a documented record. This makes it particularly suitable for production processes with high quality standards, short cycle times or end-to-end traceability.

Industrial image processing and AOI

Industrial image processing forms the basis of many AOI systems. AOI stands for automatic optical inspection and refers to the automated inspection of products, assemblies, packaging or surfaces using optical methods.

AOI systems check directly on the production line whether defined quality criteria are met. Defective products can be detected, rejected or documented before they proceed to the next stage of the process.

OCTUM develops AOI systems for a range of inspection tasks – from simple presence checks to complex 100% in-line inspections involving multiple cameras, lighting systems, software modules and interfaces to the production environment.

>> More about AOI systems

Typical inspection tasks in industrial image processing

Industrial image processing can be used for a wide variety of tasks. It is essential to consider the product, the defect pattern, the cycle time, the installation environment and the quality requirements as a whole.

Presence control

During the presence control, the image processing system checks whether a product, component, label, closure or packaging element is present. This allows missing components to be detected directly during the production process.

 

Completeness check

The completeness check verifies that all required components are present and correct. Typical examples include assembled components, packaging elements, kits, pipette tips, inserts or closures.
 

 

Position check

Products, components or labels are checked to ensure they are correctly positioned, aligned and placed. This is particularly important when subsequent process steps depend on precise positioning.

Surface inspection

With the right camera and lighting technology, scratches, cracks, inclusions, contaminants, damage or optical anomalies can be detected. Depending on the inspection task, either traditional image processing or deep learning is used.

 

Measurement

Machine vision systems can detect and evaluate geometric features such as distances, diameters, contours, angles, fill levels or heights. This enables dimensional deviations to be detected directly on the production line.

OCR and OCV

OCR is used to read plain text, serial numbers, batch data or variable print. OCV checks whether the recognised characters match the reference data correctly and in full.

Code check

Barcodes, Data Matrix codes, GS1 codes and other 1D or 2D codes can be read, verified and documented. This supports traceability, serialisation and process reliability.

Print control

Labels, imprints, variable data, codes and graphic elements are checked for positioning, legibility, completeness, content and print quality.

Adaptation and expansion of existing inspection systems

When new products, formats or variants are processed on a line, or additional inspection criteria are introduced, existing machine vision solutions can be expanded and adapted. This includes new features, defect patterns, documentation requirements or changes to process conditions.

 

The right technology for your application tasks

Not every testing task can be reliably solved using the same technology. That is why OCTUM combines different methods and components to create a suitable comprehensive solution.

Traditional 2D image processing

Traditional 2D image processing is suitable for many clearly defined inspection tasks. These include presence checks, position checks, dimensional checks, code checks and the detection of defined defect characteristics.
 

 

3D image processing

3D image processing is used when height information, shapes, volumes or surface textures are relevant. Techniques such as laser triangulation or shape-from-shading provide additional inspection data that cannot be reliably captured using 2D images alone.

 

Deep Learning and AI

Deep learning is particularly useful when dealing with complex defect patterns, varying surfaces or natural variations in the product image. It complements traditional image processing in situations where rule-based methods reach their limits.

 

In-house software solutions

With software solutions such as OCVis, OCTUMISEr and CV-Inspect, OCTUM supports flexible, scalable and production-ready machine vision systems – from individual inspection stations to complex multi-camera solutions.

 

Intelligent camera systems

Intelligent camera systems combine image capture and image analysis directly within a single compact unit. They are particularly well suited to decentralised inspection tasks where individual features need to be checked directly at specific points on the machine or production line.

OCTUM integrates smart camera systems wherever it makes technical sense – for example, for code verification, presence monitoring, position checking or simple quality checks with clearly defined criteria.

Lights and optics

The choice of light and optics is crucial for consistent inspection results. Often, it is not the camera alone, but the correct visualisation of the inspection feature that determines whether defects can be reliably detected.

OCTUM specifically tailors the lighting, lens, camera position and installation configuration to the product, surface, cycle time and inspection task. This produces reproducible image data that forms the basis for reliable evaluation.
 

System integration for machinery, plant and production lines

An image processing system is only successful if it is seamlessly integrated into the production process. That is why OCTUM considers not only the optical inspection itself, but the entire application environment.

This includes the camera, optics, lighting and software, as well as the mechanical components, interfaces, user interface, data connectivity, validatability and serviceability.

As a systems integrator, OCTUM works closely with machine builders, plant manufacturers and manufacturing companies. Inspection stations can be incorporated into the design phase of new plants or retrofitted into existing production lines.

Even if new formats are to be run on a system, products need to be adapted or additional inspection criteria are required, OCTUM provides support for the expansion and adaptation of existing machine vision solutions.
 

Integration into new machines

Inspection stations are incorporated into the machine design at an early stage and positioned at the relevant points in the process.

 

Retrofitting existing production lines

Machine vision systems can be integrated into existing production lines – tailored to the available space, cycle time, interfaces and operating concept.

 

Adapting to new requirements

When new products, formats or variants are processed on a line, or additional inspection criteria are introduced, existing machine vision solutions can be expanded and adapted. This includes new features, defect patterns, documentation requirements or changes to process conditions.

 

Industrial image processing for regulated production environments

In sectors such as pharmaceuticals and medical technology, test systems must not only perform reliable testing, but also deliver traceable and documentable results. Requirements relating to user management, audit trails, version control, change documentation and validability play a key role in this context.

OCTUM develops image processing solutions for production environments where process reliability, traceability and documented quality are crucial. This applies to both individual inspection stations and complex inspection systems featuring software, data connectivity and long-term support.

Traceability and documentation

Test results can be linked to product, batch or process data and documented in a traceable manner. This creates a robust data foundation for quality assurance, analysis and audit trail management.

 

Audit trail and user management

Relevant events, changes and user actions can be documented. Role-based and access control models support secure operation in a production environment.

Validatable system concepts

Machine vision systems can be tailored to the requirements of regulated production environments – including software, user interface, data connectivity and documented changes.

Why OCTUM?

OCTUM specialises in machine vision, AOI systems and optical quality inspection in demanding production environments. As a systems integrator, OCTUM develops solutions that are not viewed in isolation, but are tailored to the actual production environment.

  • 30 years’ experience in industrial image processing
  • more than 6,000 systems installed worldwide
  • in-house software solutions such as OCVis, OCTUMISEr and CV-Inspect
  • Experience in the pharmaceutical, medical technology, packaging technology and automotive sectors
  • Integration into existing machinery and new plant concepts
  • Combination of traditional image processing, 3D methods and deep learning
  • Support ranging from feasibility studies to service and training
  • Solutions for regulated production environments
     

Frequently asked questions about machine vision

When is machine vision worthwhile?

Industrial machine vision is worthwhile when products need to be inspected regularly, quickly, consistently and in a way that can be documented. It is particularly useful for high-volume production, short cycle times, safety-critical products or situations where there are strict traceability requirements.

 

What is the difference between industrial image processing and AOI?

Industrial image processing is the umbrella term for camera-based inspection systems used in manufacturing. AOI stands for automatic optical inspection and refers to the automated visual inspection of products, assemblies, surfaces or packaging.
 

 

What components make up an image processing system?

Typical components include a camera, lens, lighting, image processing software, an industrial PC or smart camera, interfaces to the machine control system, and operator and visualisation units.

Can existing systems be retrofitted?

Yes. Image processing systems can be integrated into new machine designs or retrofitted into existing production lines. The key factors are space constraints, cycle time, accessibility, lighting conditions and interfaces.
 

 

When is deep learning appropriate?

Deep learning is particularly useful when defect patterns vary significantly, surfaces are irregular, or traditional rules do not perform consistently enough. In many projects, the combination of traditional image processing and deep learning proves to be particularly effective.

 

What role does the lighting play?

Lighting is one of the most important factors in ensuring consistent test results. It plays a decisive role in determining whether relevant features are visible and can be reliably assessed.

Is industrial image processing suitable for regulated industries?

Yes. For the pharmaceutical, medical technology and other regulated sectors, image processing systems can be designed to support requirements relating to documentation, user management, audit trails, version control and validability.
 

Related topics relating to your inspection task

AOI Systems

Automated optical inspection for 100% testing, in-line quality control and reproducible test results directly within the production process.
> Find out more

 

System Integration

Machine vision and AOI are integrated into machines, systems and existing production lines – including interfaces, operating concepts and data connectivity.
> Find out more

 

Feasibility study

Do you have a specific inspection task but are still unsure whether it can be reliably carried out using image processing or AOI? OCTUM assesses the product, defect patterns, cycle time, lighting, camera and evaluation logic, thereby providing a sound basis for decision-making before you invest.

> Find out more

Do you have a challenging inspection task?

Talk to OCTUM about your requirements. Together, we will assess which vision system is technically sound, economically viable and reliable in the long term – whether for a new machine, an existing production line or additional inspection criteria.

 

OCTUM GmbH

Renntalstraße 16
74360 Ilsfeld, Germany

Tel: +49 7062 91494-0
E-Mail: info@octum.de

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