Batteries & CPG
Catch defects before they reach customers – at line speed and with consistent criteria
Battery and other consumer product lines require tight standards and high throughput. The Accella Quality Box™ uses AI-based vision to inspect every unit in real time, flag defects, and keep quality decisions consistent across shifts, lines, and plants. While the examples here focus on batteries, the same approach extends to other products manufactured at high speed.
Traditional Quality Control
❌ Traditional vision systems are prohibitively expensive; fewer inspection stations, more scrap later in the process
❌ High speed of line (1,500 products/min) challenges legacy systems
❌ Accuracy requirements (>99.9%) hard to achieve
❌ Can’t adjust to changing conditions without reprogramming
AI-powered Quality Control with the Accella Quality Box
✅ Up to 80% savings in hardware cost allow deployment of inspection stations along the entire manufacturing process
✅ Inspects every battery at line speed and accommodates further speed increases
✅ >99.99% accuracy achievable at a 100% inspection rate
✅ Flexible algorithm adjusts to changing manufacturing conditions e.g. lighting
On a typical battery line, the Accella Quality Box is installed at one or more key points in manufacturing. The same principle can be applied to other consumer products.
1️⃣ Image capture – industrial cameras capture views of the products at various stages during production
2️⃣ Model training and tuning – the AI model is trained on images of your good and bad products and different defect categories.
3️⃣ Real-time inspection – during production, every product is automatically evaluated in real time and a decision is made whether the product is OK or, if not, which defect type it has.
4️⃣ Feedback and actions – the information is passed on the the PLC and action e.g. blowing the product off the line, is taken.
5️⃣ System integration – inspection results can be sent to PLCs, MES/ERP, or other systems so quality data becomes part of your standard reporting and improvement processes.
Once deployed, the Accella Quality Box works alongside your existing automation to keep defective batteries or other products from leaving the plant. Instead of relying on sampling or occasional visual checks, you gain full coverage at the points that matter most.
Typical outcomes include:
- Lower risk of field failures, returns and recalls
- Significant savings compared to traditional vision systems
- Reduced rework and scrap through earlier detection of issues
- More consistent quality decisions lines and sites
- Better visibility into recurring defect patterns that can guide process improvements
The same core system can be configured for different stages of battery production or a variety of other CPG lines, for example:
- Food and beverage products e.g. shape, sealing failures, dents, holes, labeling errors, skewed or wrinkled labels
- Personal care, beauty and hygiene products e.g., artwork mistakes, broken seals, defective packaging
- Household and cleaning e.g., container damage and leaks, labeling errors
- Electronics sold as CPG e.g. loose parts, misaligned housings, color discrepancies vs. specification, damaged packaging
Use Cases
Battery Inspection
Inspect batteries at critical stages of production
Comprehensive monitoring of battery production
If you are considering AI inspection for battery or other consumer product lines, a short conversation can clarify where AI solutions create the most value, how a proof-of-concept would look, and what it takes to scale to multiple lines or plants.
Book a 30-minute meeting (we won’t sell you, it’s a promise)
Download the Quality Box overview
