Fill Level Inspection AI

Add a real-time inspection layer to every filled container on the line with Vision AI for fill level inspection. Roboflow extends fill-level inspection coverage to every container on every filling line.

Beverage, Food, Pharma, and Personal Care Fill Detection:

• Detect fill level on bottles (glass, PET, HDPE), aluminum cans (12-oz, 16-oz, tall-boy, 24-oz), aseptic cartons, pharma vials (2R, 6R, 10R, 15R, 20R, 30R, 50R per ISO 8362), ampoules, prefilled syringes (per ISO 11040), IV bags, jars, tubs, tubes, and industrial pails at sub-millimeter fill-height accuracy
• Handle challenging fill scenarios: foam interference on beer, soda, and champagne lines, meniscus variation on translucent containers, opaque containers (dairy, personal care, industrial chemicals) via X-ray or fill-height triangulation, viscous product settling (honey, sauces, gels), and headspace variation on hot-fill and vacuum-packaged products
• Verify container presence, container-type match, cap and closure presence and orientation, and primary-label presence in the same inspection pass so the line rejector is fed a single comprehensive pass/fail decision, not three separate checks

Foam, Meniscus, Headspace, and Container Integrity:

• Discriminate foam from underfill on beer, soda, sparkling water, and champagne lines where foam obscures the true liquid level and rule-based backlight vision rejects good bottles
• Measure meniscus curvature on translucent containers, headspace volume on hot-fill and vacuum-packaged products, and settle-fill drift on viscous products (honey, sauces, gel), with the model trained on your actual product-viscosity profile
• Detect fill contamination (bubbles, particles, foreign matter, glass shards, fill-nozzle drip) in clear liquids at pharma sterile fill-finish, plus USP  Visible Particulates classification, USP  sub-visible tracking, and integration with automated visual inspection machines from Bosch/Syntegon, Seidenader, Brevetti CEA, Eisai, Körber Pharma, IMA, Marchesini, and Groninger

NIST, OIML, USP Compliance and Line Integration:

• Integrate with filling equipment (Krones, Sidel, KHS, GEA, Pneumatic Scale Angelus, Serac, Bosch/Syntegon, IMA, Marchesini, Groninger, Tetra Pak, SIG Combibloc, Elopak), inspection systems (Heuft, Filtec, Miho, Krones Checkmat, PressCo, Sacmi), checkweighers (Mettler-Toledo Hi-Speed, Ishida, Anritsu, Sesotec, Loma), and X-ray inspection (Mettler-Toledo Safeline, Ishida, Anritsu, Sesotec, Loma X-ray, Bizerba)
• Feed real-time reject decisions to the PLC rejector (pneumatic pusher, star-wheel diverter, air-blast reject, drop-out gate) so misfilled containers are removed before capping or labeling, plus offset-correction commands upstream to the filler-head controller to trim individual nozzles before the process drifts out of tolerance on SPC alerts
• Log every fill inspection with per-container confidence, image crop, measured fill height and volume, target fill volume, tolerance band, pass/fail decision, timestamp, container SKU, line ID, filler head ID, and operator ID for NIST Handbook 133 audit records, OIML R87 documentation, EU 76/211/EEC e-mark three-lot statistical qualification, USP  pharma batch records, TTB alcohol beverage compliance, and FDA 21 CFR Part 210/211 cGMP evidence

Bring intelligence to every fill today. Stop underfills, overfills, and missing containers from becoming weights-and-measures citations, USP  batch investigations, product-giveaway losses, or foam-false-reject yield loss.

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More About Fill Level Inspection

What is fill level inspection with Vision AI?

Fill level inspection with Vision AI uses computer vision models on backlit inspection cameras, X-ray inspection stations, checkweighers, 3D depth sensors, pharma fill-finish isolator cameras, and aseptic filler cameras to detect fill level on bottles, cans, aseptic cartons, pharma vials, ampoules, prefilled syringes, IV bags, jars, tubs, and industrial pails at sub-millimeter accuracy, discriminate foam from underfill on carbonated beverages, measure meniscus and headspace on translucent containers, detect fill contamination in clear pharma injectables, and verify container presence, container-type match, closure integrity, and primary-label presence in the same inference pass.

Can Vision AI handle foam interference, meniscus variation, and translucent containers at 80,000 bottles per hour?

Yes. Roboflow models are trained on your actual filler-exit imagery across your real product mix (beer with real foam signatures at your carbonation level, translucent water at your specific bottle geometry, opaque dairy under X-ray, viscous honey with settle-fill drift, sterile pharma injectable under isolator lighting) and produce fill-height estimates with confidence scores that let the line PLC decide between accept, reject, or hand-off to a manual inspection station. The model discriminates foam vs. liquid vs. headspace as separate classes rather than as a single edge-detection threshold, which preserves yield on beer and carbonated lines where rule-based systems generate 3-8% false-reject rates from foam alone.

Does fill level inspection support NIST Handbook 133, OIML R87, EU 76/211/EEC, USP , and FDA 21 CFR Part 210/211?

Yes. Roboflow supports packaging and filling operations under NIST Handbook 133 (Checking the Net Contents of Packaged Goods), FTC Fair Packaging and Labeling Act, OIML R87 (Quantity of product in prepackages), EU 76/211/EEC (Average Weight and Volume System, e-mark qualification), state weights and measures programs, FDA 21 CFR Part 101 (food labeling), FDA 21 CFR Part 110 and Part 117 (food cGMP and preventive controls), FDA 21 CFR Part 210 and 211 (drug cGMP), and FDA 21 CFR Part 11 (electronic records and signatures). Your quality, regulatory, and packaging engineering teams own the acceptance criteria; Roboflow provides the inspection engine that enforces them at line speed across every filled container.

Can it integrate with our filling equipment, checkweighers, MES, SPC, and PLC?

Yes. Roboflow Inference exposes a standard API supporting common packaging and pharma-filling protocols. Customers integrate with beverage and food filling equipment (Krones, Sidel, KHS, GEA, Pneumatic Scale Angelus for cans, Serac), pharma filling equipment (Bosch/Syntegon, IMA, Marchesini, Groninger, Cozzoli), aseptic cartoners (Tetra Pak, SIG Combibloc, Elopak), inspection systems (Heuft, Filtec, Miho, Krones Checkmat, PressCo, Sacmi), checkweighers (Mettler-Toledo Hi-Speed, Ishida, Anritsu, Sesotec, Loma, Bizerba), X-ray inspection (Mettler-Toledo Safeline, Ishida, Anritsu, Sesotec, Loma, Bizerba), automated visual inspection for pharma (Bosch/Syntegon AVI, Seidenader, Brevetti CEA, Eisai, Körber Pharma), MES (Rockwell FactoryTalk, Siemens Opcenter, Werum PAS-X for pharma, Emerson Syncade, AVEVA, Wonderware, Ignition), SPC (InfinityQS ProFicient, Minitab, Northwest Analytics), ERP (SAP, Oracle), and PLC controllers (Rockwell ControlLogix, Siemens SIMATIC S7, Beckhoff TwinCAT, Mitsubishi MELSEC, Omron Sysmac) that drive the line rejector through OPC UA, MQTT, REST, ISA-95, PackML, and direct database writes.