{"id":3666,"date":"2025-09-22T10:54:09","date_gmt":"2025-09-22T08:54:09","guid":{"rendered":"https:\/\/www.ki-fortschrittszentrum.de\/?post_type=projekt&#038;p=3666"},"modified":"2025-12-12T08:26:53","modified_gmt":"2025-12-12T07:26:53","slug":"ki-based-pressure-image-control-for-effervescent-tablet-tubes-at-jaco","status":"publish","type":"projekt","link":"https:\/\/www.ki-fortschrittszentrum.de\/en\/projekt\/ki-basierte-druckbildkontrolle-fuer-brausetablettenroehren-bei-jaco\/","title":{"rendered":"AI-based print image control for effervescent tablet tubes at Jaco"},"content":{"rendered":"<div class=\"wp-block-stackable-columns stk-block-columns stk-block stk-86663cd stk-block-background stk--has-background-overlay\" data-block-id=\"86663cd\"><style>.stk-86663cd {background-image:url(https:\/\/www.ki-fortschrittszentrum.de\/wp-content\/uploads\/2025\/08\/BG4-scaled.jpg) !important;min-height:520px !important;align-items:flex-end !important;padding-bottom:0px !important;margin-bottom:0px !important;display:flex !important;}<\/style><div class=\"stk-row stk-inner-blocks stk-block-content stk-content-align stk-86663cd-column\">\n<div class=\"wp-block-stackable-column stk-block-column stk-column stk-block stk-5a28863\" data-v=\"4\" data-block-id=\"5a28863\"><div class=\"stk-column-wrapper stk-block-column__content stk-container stk-5a28863-container stk--no-background stk--no-padding\"><div class=\"stk-block-content stk-inner-blocks stk-5a28863-inner-blocks\">\n<div class=\"wp-block-stackable-columns stk-block-columns stk-block stk-3e4895d\" data-block-id=\"3e4895d\"><div class=\"stk-row stk-inner-blocks stk-block-content stk-content-align stk-3e4895d-column\">\n<div class=\"wp-block-stackable-column stk-block-column stk-column stk-block stk-a094f1e\" data-v=\"4\" data-block-id=\"a094f1e\"><style>@media screen and (min-width:690px){.stk-a094f1e {flex:var(--stk-flex-grow, 1) 1 calc(30% - var(--stk-column-gap, 0px) * 2 \/ 3 ) !important;}}<\/style><div class=\"stk-column-wrapper stk-block-column__content stk-container stk-a094f1e-container stk--no-background stk--no-padding\"><div class=\"stk-block-content stk-inner-blocks stk-a094f1e-inner-blocks\"><\/div><\/div><\/div>\n\n\n\n<div class=\"wp-block-stackable-column stk-block-column stk-column stk-block stk-ba57710\" data-v=\"4\" data-block-id=\"ba57710\"><style>@media screen and (min-width:690px){.stk-ba57710 {flex:var(--stk-flex-grow, 1) 1 calc(30% - var(--stk-column-gap, 0px) * 2 \/ 3 ) !important;}}<\/style><div class=\"stk-column-wrapper stk-block-column__content stk-container stk-ba57710-container stk--no-background stk--no-padding\"><div class=\"stk-block-content stk-inner-blocks stk-ba57710-inner-blocks\"><\/div><\/div><\/div>\n\n\n\n<div class=\"wp-block-stackable-column stk-block-column stk-column stk-block stk-4764f29 stk-block-background\" data-v=\"4\" data-block-id=\"4764f29\"><style>.stk-4764f29 {align-self:flex-end !important;background-color:var(--theme-palette-color-8, #ffffff) !important;padding-top:0px !important;padding-right:0px !important;padding-bottom:0px !important;padding-left:0px !important;}.stk-4764f29-inner-blocks{justify-content:flex-end !important;}.stk-4764f29:before{background-color:var(--theme-palette-color-8, #ffffff) !important;}@media screen and (min-width:690px){.stk-4764f29 {flex:var(--stk-flex-grow, 1) 1 calc(40% - var(--stk-column-gap, 0px) * 2 \/ 3 ) !important;}}<\/style><div class=\"stk-column-wrapper stk-block-column__content stk-container stk-4764f29-container stk--no-background stk--no-padding\"><div class=\"stk--column-flex stk-block-content stk-inner-blocks stk-4764f29-inner-blocks\">\n<div class=\"wp-block-greenshift-blocks-container gspb_container gspb_container-gsbp-933ef16\" id=\"gspb_container-id-gsbp-933ef16\">\n<div class=\"wp-block-stackable-image stk-block-image has-text-align-left stk-block stk-1690316\" data-block-id=\"1690316\"><style>.stk-1690316 {margin-bottom:36px !important;}.stk-1690316 .stk-img-wrapper{width:50% !important;}<\/style><figure><span class=\"stk-img-wrapper stk-image--shape-stretch\"><img loading=\"lazy\" decoding=\"async\" class=\"stk-img\" src=\"https:\/\/www.ki-fortschrittszentrum.de\/wp-content\/uploads\/2025\/09\/logo.png\" width=\"50\" height=\"300\"\/><\/span><\/figure><\/div>\n\n\n\n<div class=\"wp-block-stackable-text stk-block-text stk-block stk-97d4068\" data-block-id=\"97d4068\"><style>.stk-97d4068 {margin-bottom:12px !important;}.stk-97d4068 .stk-block-text__text{font-size:16px !important;line-height:1.4em !important;font-weight:500 !important;font-style:italic !important;font-family:Constantia, Lucida Bright, Lucidabright, \"Lucida Serif\", Lucida, \"DejaVu Serif\", \"Bitstream Vera Serif\", \"Liberation Serif\", Georgia, serif !important;}@media screen and (max-width:999px){.stk-97d4068 .stk-block-text__text{font-size:16px !important;}}<\/style><p class=\"stk-block-text__text\"><\/p><\/div>\n\n\n\n<div class=\"wp-block-greenshift-blocks-container gspb_container gspb_container-gsbp-eafe0ac\" id=\"gspb_container-id-gsbp-eafe0ac\">\n<div class=\"wp-block-stackable-text stk-block-text stk-block stk-25dc0f8\" data-block-id=\"25dc0f8\"><style>.stk-25dc0f8 {padding-top:0px !important;padding-bottom:0px !important;margin-top:0px !important;margin-bottom:0px !important;}.stk-25dc0f8 .stk-block-text__text{font-size:15px !important;}@media screen and (max-width:999px){.stk-25dc0f8 .stk-block-text__text{font-size:15px !important;}}<\/style><p class=\"stk-block-text__text has-text-align-left\"><\/p><\/div>\n\n\n\n<div class=\"wp-block-stackable-text stk-block-text stk-block stk-d634667\" data-block-id=\"d634667\"><style>.stk-d634667 {align-items:flex-start !important;padding-top:0px !important;padding-bottom:0px !important;margin-top:0px !important;margin-bottom:0px !important;display:flex !important;}.stk-d634667 .stk-block-text__text{font-size:15px !important;font-weight:200 !important;}@media screen and (max-width:999px){.stk-d634667 .stk-block-text__text{font-size:15px !important;}}<\/style><p class=\"stk-block-text__text has-text-align-left\">Jaco Dr. Jaeniche GmbH &amp; Co.<\/p><\/div>\n<\/div>\n<\/div>\n\n\n\n<div class=\"wp-block-greenshift-blocks-container gspb_container gspb_container-gsbp-1fa6a74\" id=\"gspb_container-id-gsbp-1fa6a74\">\n<div class=\"wp-block-stackable-text stk-block-text stk-block stk-be1fdb3\" data-block-id=\"be1fdb3\"><style>.stk-be1fdb3 {padding-top:0px !important;padding-bottom:12px !important;margin-top:0px !important;margin-bottom:0px !important;}.stk-be1fdb3 .stk-block-text__text{font-size:15px !important;color:#ffffff80 !important;}@media screen and (max-width:999px){.stk-be1fdb3 .stk-block-text__text{font-size:15px !important;}}<\/style><p class=\"stk-block-text__text has-text-color has-text-align-left\">Contact at the AI Innovation Center<\/p><\/div>\n\n\n\n<div class=\"wp-block-stackable-text stk-block-text stk-block stk-24ffa5e\" data-block-id=\"24ffa5e\"><style>.stk-24ffa5e {padding-top:0px !important;padding-bottom:0px !important;margin-top:0px !important;margin-bottom:0px !important;}.stk-24ffa5e .stk-block-text__text{font-size:15px !important;color:#ffffff !important;}@media screen and (max-width:999px){.stk-24ffa5e .stk-block-text__text{font-size:15px !important;}}<\/style><p class=\"stk-block-text__text has-text-color has-text-align-left\">Andreas Frommknecht<\/p><\/div>\n\n\n\n<div class=\"wp-block-stackable-button-group stk-block-button-group stk-block stk-af007b4\" data-block-id=\"af007b4\"><style>.stk-af007b4 {padding-top:0px !important;padding-right:0px !important;padding-bottom:0px !important;padding-left:0px !important;margin-top:0px !important;margin-right:0px !important;margin-bottom:0px !important;margin-left:0px !important;}<\/style><div class=\"stk-row stk-inner-blocks stk-block-content stk-button-group\">\n<div class=\"wp-block-stackable-button stk-block-button is-style-plain stk-block stk-1cf8bea\" data-block-id=\"1cf8bea\"><style>.stk-1cf8bea .stk-button{padding-top:0px !important;padding-right:0px !important;padding-bottom:0px !important;padding-left:0px !important;background:transparent !important;}.stk-1cf8bea .stk-button:hover:after{background:transparent !important;opacity:1 !important;}:where(.stk-hover-parent:hover,  .stk-hover-parent.stk--is-hovered) .stk-1cf8bea .stk-button:after{background:transparent !important;opacity:1 !important;}.stk-1cf8bea .stk-button__inner-text{font-size:15px !important;color:var(--theme-palette-color-8, #ffffff) !important;font-weight:200 !important;}@media screen and (max-width:999px){.stk-1cf8bea .stk-button__inner-text{font-size:15px !important;}}<\/style><a class=\"stk-link stk-button stk--hover-effect-darken\" href=\"mailto:andreas.frommknecht@ipa.fraunhofer.de\" title=\"andreas.frommknecht@ipa.fraunhofer.de\"><span class=\"has-text-color stk-button__inner-text\">andreas.frommknecht@ipa.fraunhofer.de<\/span><\/a><\/div>\n<\/div><\/div>\n<\/div>\n<\/div><\/div><\/div>\n<\/div><\/div>\n<\/div><\/div><\/div>\n<\/div><\/div>\n\n\n\n<div class=\"wp-block-stackable-spacer stk-block-spacer stk--no-padding stk-block stk-56a43b6\" data-block-id=\"56a43b6\"><\/div>\n\n\n\n<div class=\"wp-block-stackable-columns stk-block-columns stk-block stk-fc04401\" data-block-id=\"fc04401\"><style>.stk-fc04401 {padding-right:24px !important;padding-left:24px !important;}<\/style><div class=\"stk-row stk-inner-blocks stk-block-content stk-content-align stk-fc04401-column\">\n<div class=\"wp-block-stackable-column stk-block-column stk-column stk-block stk-a194320\" data-v=\"4\" data-block-id=\"a194320\"><div class=\"stk-column-wrapper stk-block-column__content stk-container stk-a194320-container stk--no-background stk--no-padding\"><div class=\"stk-block-content stk-inner-blocks stk-a194320-inner-blocks\"><div data-block=\"hook:1248\" class=\"alignfull\"><article id=\"post-1248\" class=\"post-1248\"><div class=\"entry-content is-layout-constrained\">\n<div class=\"wp-block-stackable-button-group stk-block-button-group stk-block stk-fcd1a8a\" data-block-id=\"fcd1a8a\"><style>.stk-fcd1a8a {margin-bottom:24px !important;}<\/style><div class=\"stk-row stk-inner-blocks stk-block-content stk-button-group\">\n<div class=\"wp-block-stackable-icon-button stk-block-icon-button stk-block stk-82470ba is-style-ghost\" data-block-id=\"82470ba\"><style>.stk-82470ba .stk-button{background:transparent !important;}.stk-82470ba .stk-button:hover{background:transparent !important;opacity:1 !important;}:where(.stk-hover-parent:hover,  .stk-hover-parent.stk--is-hovered) .stk-82470ba .stk-button:after{background:transparent !important;opacity:1 !important;}.stk-82470ba .stk-button:before{border-style:solid !important;border-color:var(--theme-palette-color-9, #264e5d) !important;}.stk-82470ba .stk-button .stk--inner-svg svg:last-child, .stk-82470ba .stk-button .stk--inner-svg svg:last-child :is(g, path, rect, polygon, ellipse){fill:var(--theme-palette-color-11, #006e92) !important;}<\/style><a class=\"stk-link stk-button stk--hover-effect-darken\" href=\"javascript:window.history.back();\" title=\"Back\"><span class=\"stk--svg-wrapper\"><div class=\"stk--inner-svg\"><svg xmlns=\"http:\/\/www.w3.org\/2000\/svg\" viewbox=\"0 0 512 512\" aria-hidden=\"true\" width=\"32\" height=\"32\"><path d=\"M9.4 233.4c-12.5 12.5-12.5 32.8 0 45.3l128 128c12.5 12.5 32.8 12.5 45.3 0s12.5-32.8 0-45.3L109.3 288 480 288c17.7 0 32-14.3 32-32s-14.3-32-32-32l-370.7 0 73.4-73.4c12.5-12.5 12.5-32.8 0-45.3s-32.8-12.5-45.3 0l-128 128z\"><\/path><\/svg><\/div><\/span><\/a><\/div>\n<\/div><\/div>\n<\/div><\/article><\/div>\n\n\n\n<div class=\"wp-block-stackable-heading stk-block-heading stk-block-heading--v2 stk-block stk-5cbd537\" id=\"quick-check\" data-block-id=\"5cbd537\"><style>.stk-5cbd537 {margin-bottom:0px !important;}<\/style><h1 class=\"stk-block-heading__text\">AI-based print image control for effervescent tablet tubes at Jaco<\/h1><\/div>\n\n\n\n<div class=\"wp-block-stackable-icon-label stk-block-icon-label stk-block stk-9c593c0\" id=\"quick-check\" data-block-id=\"9c593c0\"><style>.stk-9c593c0 .stk-inner-blocks{gap:8px !important;}<\/style><div class=\"stk-row stk-inner-blocks stk-block-content\">\n<div class=\"wp-block-stackable-icon stk-block-icon has-text-align-left stk-block stk-624347f\" data-block-id=\"624347f\"><style>.stk-624347f .stk--svg-wrapper .stk--inner-svg svg:last-child{height:16px !important;width:16px !important;}.stk-624347f .stk--svg-wrapper .stk--inner-svg svg:last-child, .stk-624347f .stk--svg-wrapper .stk--inner-svg svg:last-child :is(g, path, rect, polygon, ellipse){fill:var(--theme-palette-color-10, #25bae2) !important;}<\/style><span class=\"stk--svg-wrapper\"><div class=\"stk--inner-svg\"><svg style=\"height:0;width:0\"><defs><lineargradient id=\"linear-gradient-624347f\" x1=\"0\" x2=\"100%\" y1=\"0\" y2=\"0\"><stop offset=\"0%\" style=\"stop-opacity:1;stop-color:var(--linear-gradient-624347-f-color-1)\"><\/stop><stop offset=\"100%\" style=\"stop-opacity:1;stop-color:var(--linear-gradient-624347-f-color-2)\"><\/stop><\/lineargradient><\/defs><\/svg><svg data-prefix=\"fa\" data-icon=\"star\" class=\"svg-inline--fa fa-star fa-w-18\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\" viewbox=\"0 0 576 512\" aria-hidden=\"true\" width=\"32\" height=\"32\"><path fill=\"currentColor\" d=\"M259.3 17.8L194 150.2 47.9 171.5c-26.2 3.8-36.7 36.1-17.7 54.6l105.7 103-25 145.5c-4.5 26.3 23.2 46 46.4 33.7L288 439.6l130.7 68.7c23.2 12.2 50.9-7.4 46.4-33.7l-25-145.5 105.7-103c19-18.5 8.5-50.8-17.7-54.6L382 150.2 316.7 17.8c-11.7-23.6-45.6-23.9-57.4 0z\"><\/path><\/svg><\/div><\/span><\/div>\n\n\n\n<div class=\"wp-block-stackable-heading stk-block-heading stk-block-heading--v2 stk-block stk-cdc2d3f\" id=\"span-data-stk-dynamic-current-page-post-taxonomy-term-projektformat-contenteditable-false-class-stk-dynamic-content-post-taxonomy-placeholder-span\" data-block-id=\"cdc2d3f\"><p class=\"stk-block-heading__text\">Quick Check<\/p><\/div>\n<\/div><\/div>\n\n\n\n<div class=\"wp-block-stackable-heading stk-block-heading stk-block-heading--v2 stk-block stk-c21bed1\" id=\"ausgangssituation\" data-block-id=\"c21bed1\"><h2 class=\"stk-block-heading__text\">Initial situation<\/h2><\/div>\n\n\n\n<div class=\"wp-block-stackable-text stk-block-text stk-block stk-65e3563\" data-block-id=\"65e3563\"><style>.stk-65e3563 {column-count:1 !important;}<\/style><p class=\"stk-block-text__text\">Jaco Dr. Jaeniche GmbH &amp; Co. KG is the European market leader for effervescent tablet tubes and produces over 300 million printed articles annually with a total reject rate of less than 5 percent. As a manufacturer of primary packaging for the pharmaceutical and food sectors, the highest quality requirements apply. The print image was checked manually on eight out of nine printing presses by means of spot checks. A camera system already existed on one machine, but its high sensitivity led to increased pseudo errors and unnecessarily high reject rates. The challenge was to distinguish real printing errors from system-related false alarms in order to enable a comprehensive automated 100 percent inspection without excessive waste. Existing systems could not differentiate between actual quality defects and technically induced pseudo-errors. This prevented fully automated implementation and continued to require manual monitoring.<\/p><\/div>\n\n\n\n<div class=\"wp-block-stackable-heading stk-block-heading stk-block-heading--v2 stk-block stk-8c26049\" id=\"losungsidee\" data-block-id=\"8c26049\"><h2 class=\"stk-block-heading__text\">Solution idea<\/h2><\/div>\n\n\n\n<div class=\"wp-block-stackable-text stk-block-text stk-block stk-ab6a506\" data-block-id=\"ab6a506\"><style>.stk-ab6a506 {column-count:1 !important;}<\/style><p class=\"stk-block-text__text\">Development of AI-based anomaly detection to intelligently distinguish between real print defects and pseudo defects. The solution includes multi-stage image pre-processing with line offset correction and robust template matching to precisely position the inspection windows. The AI model is trained exclusively on error-free reference images and uses memory bank technology for compressed storage of relevant image properties. This anomaly detection identifies deviations from the norm, enabling reliable automated print image inspection without excessive reject rates.<\/p><\/div>\n\n\n\n<div class=\"wp-block-stackable-image stk-block-image has-text-align-left stk-block stk-2fa484b\" data-block-id=\"2fa484b\"><style>.stk-2fa484b .stk-img-figcaption{font-size:12px !important;}.stk-2fa484b .stk-img-wrapper{width:484px !important;}@media screen and (max-width:999px){.stk-2fa484b .stk-img-figcaption{font-size:12px !important;}}<\/style><figure><span class=\"stk-img-wrapper stk-image--shape-stretch stk--has-lightbox\"><img loading=\"lazy\" decoding=\"async\" class=\"stk-img wp-image-3669\" src=\"https:\/\/www.ki-fortschrittszentrum.de\/wp-content\/uploads\/2025\/09\/Jaco_Steckbrief_img_V2.png\" width=\"484\" height=\"224\" alt=\"Figure 1\" srcset=\"https:\/\/www.ki-fortschrittszentrum.de\/wp-content\/uploads\/2025\/09\/Jaco_Steckbrief_img_V2.png 484w, https:\/\/www.ki-fortschrittszentrum.de\/wp-content\/uploads\/2025\/09\/Jaco_Steckbrief_img_V2-400x185.png 400w, https:\/\/www.ki-fortschrittszentrum.de\/wp-content\/uploads\/2025\/09\/Jaco_Steckbrief_img_V2-18x8.png 18w\" sizes=\"auto, (max-width: 484px) 100vw, 484px\" \/><\/span><figcaption class=\"stk-img-figcaption\">Figure 1<\/figcaption><\/figure><\/div>\n\n\n\n<div class=\"wp-block-stackable-heading stk-block-heading stk-block-heading--v2 stk-block stk-76475ee\" id=\"nutzen\" data-block-id=\"76475ee\"><h2 class=\"stk-block-heading__text\">Benefit<\/h2><\/div>\n\n\n\n<div class=\"wp-block-stackable-text stk-block-text stk-block stk-3e86ca0\" data-block-id=\"3e86ca0\"><p class=\"stk-block-text__text\">The project shows that 100 percent control of all print images without excessive reject rates is possible with a combination of rule-based image pre-processing and AI-based methods for anomaly detection. Reducing the pseudo error rate by an average of 85.7 percent has the potential for significant efficiency gains and cost savings. Reliable automated monitoring relieves the burden on personnel, enabling more machines to be operated and counteracting the shortage of skilled workers. This leads to a competitive advantage through the highest product quality with optimized production costs.<\/p><\/div>\n\n\n\n<div class=\"wp-block-stackable-heading stk-block-heading stk-block-heading--v2 stk-block stk-1e747a7\" id=\"umsetzung-der-ki-applikation\" data-block-id=\"1e747a7\"><h2 class=\"stk-block-heading__text\">Implementation of the AI application<\/h2><\/div>\n\n\n\n<div class=\"wp-block-stackable-text stk-block-text stk-block stk-d745445\" data-block-id=\"d745445\"><p class=\"stk-block-text__text\">The solution was technically implemented as follows: Firstly, through a two-stage rule-based image pre-processing with a correction of the line offset caused by the image acquisition; and secondly, through template matching using a master image to counteract a possible offset during image acquisition during unwinding and thus correct the position of the measurement window. The anomaly detection was trained on 50 error-free reference images and evaluated on error and pseudo error images provided by Jaco. The described procedure was tested on 6 different print images, whereby the pseudo error rate could be reduced by 85.7 percent on average.<\/p><\/div>\n\n\n\n<p>The technology enables continuous improvement by integrating new data into the training data set. For Jaco, as the European market leader, this represents an important technological advance in supplying large contract manufacturers in the regulated pharmaceutical and food sectors.<\/p>\n<\/div><\/div><\/div>\n<\/div><\/div>\n\n\n\n<p><\/p>","protected":false},"excerpt":{"rendered":"<p>The project developed an AI-based, reliable and fully automated solution for print image monitoring. 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