This paper presents a deep learning-based framework for automating the visual inspection of plastic bottles in an Industry 4.0 context, detecting surface defects to enhance product quality. Our contributions include the acceleration of model development through knowledge transfer learning, an inventive data generation strategy that combines physical samples with synthetic data augmentation techniques, an extensive evaluation of pre-trained deep convolutional neural networks, and a user-friendly interface for real-time quality inspection reporting and making the information easily accessible and actionable. In comparison to existing methods, our proposed method outperforms with a higher Accuracy to Size Ratio of 7.0. This characteristic underscores its capacity to efficiently and accurately classify and detect defects across multiple classes while maintaining a low area utilization. This feature not only demonstrates its exceptional performance but also positions it as a practical solution for real-world scenarios with resource constraints.

With the increasing utilization of plastic bottles in the fast-moving consumer goods industry, the efficiency and accuracy of the bottle defect inspection process becomes very important for quality assurance. Deep-learning-based inspection is accurate and robust, but at the same time data hogging and computationally expensive. Thus, it is not feasible for fast inspection. Therefore, this paper presents an efficient and fast machine-vision-based system for inspecting plastic bottle defects. The system is composed of a chamber which has a camera and illuminators to capture high-resolution images in controlled lighting conditions. Captured images are processed by using simple image processing techniques to identify multiple defects such as seated cap, dents on the body and label alignment on the plastic. The experimental results show that the proposed system is 95% accurate in determining a range of bottle defects. It is highly feasible for fast inspection and does not require high computation power and a large amount of training data.