Primacy: Automated Candle Alignment & Counting System

Inconsistent Quality and Bottlenecks in Production

Manual visual inspection at the wax-filling stage led to alignment inconsistencies, human errors, and reduced throughput. The process required dedicated QC personnel and created a bottleneck in achieving optimal production speed.

• Inconsistent candle alignment caused rework and wastage.
• Manual counting errors affected batch integrity and inventory.
• Production slowdowns due to manual quality checks.

AI-Powered Vision Automation for Precision QC

Sunbio IT Solutions implemented a vision automation solution with real-time object detection using dual high-speed GigE cameras and AI models trained for candle alignment and counting precision.

• AI Object Detection: ±0.5 mm accuracy tolerance for wick alignment.
• Automated Gate Control: PLC-integrated stop signal for misaligned trays.
• Continuous Monitoring: Real-time feedback loop for production control.

Operational Excellence and Cost Optimization

Primacy achieved higher production throughput, reduced operational costs, and elevated quality consistency through automation-driven precision.

Toward a Fully Autonomous Production Line

• Robotic Integration: Cobots for auto-correction of misaligned trays.
• Enhanced Vision System: Camera-assisted tray loading automation.