Efficient inline quality control with RadarImager

3D imaging system Making invisible objects visible

2024-07-05 Source: Balluff | Translated by AI 4 min Reading Time

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Balluff's Radar Imager, an advanced industrial 3D imaging system, examines packaging for completeness, integrity, and the presence of foreign bodies. This system enables customers to benefit from efficient inline quality control, ensuring high standards and consistency in their production processes.

The RadarImager is used, among other things, in the cosmetics and pharmaceutical industry. In the case of medications and dietary supplements, quality assurance plays a crucial role.(Image: Balluff) — The RadarImager is used, among other things, in the cosmetics and pharmaceutical industry. In the case of medications and dietary supplements, quality assurance plays a crucial role.
(Image: Balluff)

Pharmaceutical products often place high demands on packaging and logistics concepts. Added to this is the fact that in 2022 the Drug Commission of German Pharmacies (AMK) received 7,182 spontaneous reports of suspected quality deficiencies and adverse effects of drugs from 4,049 different (hospital) pharmacies. Among the 4,843 quality deficiencies, packaging errors were, as in previous years, most frequently reported (2022: 2180 = 45%). This requires flexible production lines with a 100% inline quality control at the end of the packaging process.

According to the Federal Office for Consumer Protection and Food Safety, there were a total of 46 reports of foreign bodies found in food in 2023. Therefore, the food industry is about ensuring that no products come onto the market that might contain foreign bodies.

How does radar imaging work?

Today, a variety of technologies are used in production for quality control. These include, among others, optical systems that cannot see through the packaging material, continuous trolleys that do not provide information about the error case, and X-ray inspection. The latter require expensive protective devices, due to the ionizing X-rays, and a radiation officer. However, while X-ray analysis can reliably detect metals in packaging, it does not work properly with glass, plastic, and wood splinters.

3D imaging system based on radar technology

This is exactly where Balluff's RadarImager comes in. The industrial 3D imaging system—based on radar technology—examines various types of packaging. It enables all kinds of "hidden objects" to be detected. It checks packaging for completeness, product integrity, identifies foreign bodies and thus raises quality control to a new level.

The frequency range of the used radar radiation lies in the electromagnetic spectrum between microwave and infrared, so the waves used are not ionizing, thus harmless to health. Balluff has now developed with its radar sensor a compact, powerful system that integrates perfectly into production and safely scans products and packaging. Based on the results, errors can be reliably identified.

The sensor emits electromagnetic waves

The sensor emits electromagnetic waves that can penetrate non-conductive products. Each material absorbs the wave energy specifically, which accordingly reduces their amplitude. The additional reflection at interfaces generates runtime differences between the original and the reflected wave.

The specialized software used translates the measured amplitude and runtime differences into images. The system thus creates up to ten image stacks per second covering the entire area under the Radar Imager. The evaluation of the image stack forms the basis of the quality check. Since each image has its own timestamp, exact traceability is possible.

Document and check

The data thus obtained document found irregularities and foreign bodies or check whether packaging is complete and intact. "With the radar imager, we support our customers in increasing process reliability and avoiding possible recalls and the costs arising from them", says Jörg Maier, Strategic Incubation Manager at Balluff. "It continuously monitors the manufacturing process and the measurement can be directly integrated into the production line. Since the radar imager is placed directly above the conveyor belt, this also has a positive effect on the machine length."

Capture the surface condition

In the used frequency range, the radar beams can penetrate all dielectric materials such as foils, cartons and plastics. Metal, conductive objects and liquids can be detected, but not penetrated. Thus, it is possible to find metallic objects or particles and detect fill levels. In addition, the sensor allows the surface texture of different materials to be captured.

Due to the used frequency range, the imager can optically safely separate dielectric objects at a distance of a few millimeters. Even when objects are closer together, important information can still be gained, and this at belt speeds up to 1.5 m/S or 90 m/minute. However, to be able to measure with the necessary precision, the RadarImager requires continuous movement of the product conveyor belt or its position and a clear view of the products to be checked.

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Date: 08.12.2025

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When the sensor is set up in the production line, it only needs suitable testing software to evaluate the images. If the product changes, only the new "recipe" has to be loaded. This way, the radar sensor can also check contents of packaging for completeness including inserts and integrity, detect foreign bodies, or recognize fill levels in the food and beverage sector.

The benefits of radar measurements

The new robust radar sensor from Balluff—an industrial 3D imaging system—offers important advantages. It is characterized by its high accuracy and reliability and also offers a wide range of configuration options. The compact sensor can be easily integrated into existing product lines via plug & play. Calibration is then carried out by the customer. It is maintenance-free, offers user-friendly operation, acts precisely and reliably even under unfavorable lighting conditions, and delivers optimal results even with dust, smoke, moisture and rough surfaces without affecting the product itself. This makes the radar imager an attractive alternative to currently used technologies and opens up new solutions in the field of quality control for food, pharma, cosmetics, packaging, and logistics.