What it catches
Video-to-Action AI checks every bar that passes the camera, not a sample. On a chocolate line it flags:
- Surface scratches and scuffs
- Broken or chipped bars
- Misshapen or incomplete bars
- Discoloration and uneven surfaces that change how the bar looks to the customer
- Packaging faults after wrapping: damaged wrap, broken seals and incorrect labels
Why manual checks miss it
Chocolate lines move too fast for people to look at every bar, so manual inspection relies on sampling, and defects between samples go through. Small scratches and cracks on a glossy, dark surface are easy to miss, and attention drops over a long shift. In our customer story, the manufacturer found manual inspection time-consuming, labor-intensive and prone to error, even with quality controls in place.
How it acts
VITA, Maneva's quality and downtime agent, decides on every bar in real time: accept, reject or reroute. It can make up to 30 quality decisions per second, so inspection keeps pace with the line instead of slowing it.
A rejected bar is removed by the line's reject mechanism, such as a pusher or air jet, before it reaches packaging. Each decision is logged with its image, so the quality team can review exactly what was rejected and why.
Defect counts are tracked live. When the same defect starts repeating, the line team can check the molds or conveyor before more bars are affected, instead of finding the problem at the end of the shift.
Where it sits on the line
The camera watches the bars from above as they travel along the conveyor, ahead of the reject point and before wrapping. A second view after wrapping can check the finished pack.
Some lines can start with cameras they already have; many need at least one off-the-shelf camera placed for the task. Maneva helps choose the camera and where to put it, then trains the model on images of your own good and defective bars.
Result
A premium chocolate manufacturer moved from sampling to AI inspection of every bar, reaching up to 99.9% detection accuracy across surface defects, breaks and packaging flaws, with fewer false calls than manual inspection. Read the customer story.
More for confectionery plants: AI for confectionery lines →
Frequently Asked Questions
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