Recycling of packaging in bottled beverage industry
The project addressed the challenge of recycling packaging in the bottled beverage industry by developing, implementing, and optimizing an AI-based quality analysis system. The core objective was to detect and remove defective bottles directly on the production line, thereby reducing waste, improving sustainability, and maintaining high production efficiency. The project aimed for a universal solution adaptable for broader industry use.
Why it matters
The bottled beverage industry faces the dual challenge of ensuring high production efficiency while reducing waste and improving sustainability. Defective bottles—whether due to misprints, cap issues, or incorrect fill levels—often lead to unnecessary plastic waste, energy use, and resource loss. Finding a way to detect and remove these defects early in production is key to supporting the green and digital transition of the industry.
What we built
Together with Birštono Mineraliniai Vandenys (BMV) and BENCO Baltic Engineering Company, we developed and implemented an AI-powered computer vision quality analysis system. The solution integrates directly into production lines and operates in real time, detecting defects across three key stages:
- Early stage: identifying PET preform color deviations before processing.
- Mid-stage: checking labels for discolouration or misprints.
- Final stage: verifying fill levels, cap condition, and expiry date.
Built with edge AI technology (Intel NUC and Raspberry Pi systems paired with industrial cameras), the system maintains full production speeds of 15,000–22,000 bottles per hour without disrupting workflows.
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Embracing global challenges for agrifood excellence
Impact so far
- Achieved over 90% precision in defect detection.
- Reduced up to 90% of unacceptable products reaching the market.
- Significantly lowered plastic waste and energy use by catching defects early.
- Demonstrated that cost-effective, modular AI solutions can be successfully scaled in industrial environments.
- Strengthened digital maturity and innovation culture within both partners, ensuring staff and systems are better equipped for future transitions.
What happens next
Both partners are scaling their ambitions:
- BMV will upgrade production lines for higher speeds, explore new product designs, and pursue R&D for functional food products—all supported by enhanced quality assurance.
- Benco will continue R&D in adaptive AI algorithms, lighting solutions, and modular hardware to expand deployment into other sectors such as food processing, pharmaceuticals, and packaging.
This project shows how interregional innovation can accelerate the twin transition—digital and green—and position European SMEs at the forefront of sustainable, competitive manufacturing.
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