INTRAVIS: Technology that Supports Maintenance Teams

At INTRAVIS, we’ve always seen ourselves as a partner to our customers and their teams. But what does that actually mean? Which roles within our customers’ operations do we support – and how?
In this blog series, we take a closer look at four key user groups and show how our technologies make their work easier. In todays edition: maintenance teams.

In this edition of our series, we focus on a frequently underestimated yet crucial target group: the maintenance team. After all, only well-maintained equipment can consistently produce high-quality products—and this is precisely where our technologies come into play. They support maintenance not just reactively, but in a targeted and predictive manner.

Pinpointing Error Sources: Component-Specific Quality Statistics

Our inspection systems don’t just detect that a product is defective—they also show where and why. Component-specific quality statistics enable your maintenance team to precisely identify where in the production process issues are occurring—far beyond simple cavity analysis:

• Cavity Analysis: Identifies which cavities in the injection mold are most frequently responsible for defective products.
• Carriers: Detects whether specific carriers regularly cause production issues and require optimization.
• Label Applicator Heads: Highlights which applicator heads are more prone to labeling errors, such as misalignment or adhesive issues.
• Spindles: Correlates defects with specific spindles to identify systematic errors.
• Filler/Capper Units: Determines which filling or capping units are systematically responsible for deviations in fill level or closure quality.

Benefits for Your Team:

Instead of troubleshooting based on guesswork, maintenance can be targeted at the affected components. This saves time, reduces unnecessary maintenance, and increases equipment availability. Root cause analysis for recurring issues is also significantly accelerated—a clear advantage for efficient maintenance.

Applications:

Closure inspection, Label inspection, Bottle and container inspection, Preform inspection

Predictive Maintenance via Trend Analysis with the IntraVisualizer

Many defects don’t occur suddenly—they develop gradually due to factors like material fatigue, wear, or temperature drift. IntraVisualizer analyzes quality data over extended periods and identifies:

• Long-term trends in product quality
• Recurring patterns that indicate impending issues
• Forecasts of when tolerance limits are likely to be exceeded

Benefits for Your Team:

Maintenance can be scheduled before failures or scrap occur. This increases planning reliability, reduces downtime, and enables more efficient use of resources.

Applications:

Closure inspection, Label inspection, Bottle and container inspection, Preform inspection

Immediate Response to Sudden Errors: Active Notifications

Not all defects give advance warning—some occur suddenly and require immediate action. In such cases, every minute counts. That’s why the IntraVisualizer includes an active notification feature that alerts your team instantly:

• Via email, app notification, or SMS
• As soon as consistently defective products are detected
• With direct reference to the affected production line or cavity

Benefits for Your Team:

Rapid response to acute issues prevents unnecessary scrap, reduces material loss, and ensures stable production.

Applications:

Closure inspection, Label inspection, Bottle and container inspection, Preform inspection

Proactive Action with System Self-Monitoring

All our systems come standard with integrated self-monitoring that continuously analyzes the condition of all critical components. Various signals and system elements are monitored to detect irregularities early:

• Monitoring of pulse and trigger signals, lighting units, and cameras
• Expandable with additional sensors depending on system configuration
• Automatic detection of abnormal operating conditions
• Immediate error reporting and halt of inspection in case of malfunction
• Prevention of uninspected objects passing through the system

Additionally, the system provides recommendations on which components—such as lighting units or cameras—should be replaced soon. This allows maintenance to be planned precisely and in a timely manner.

Benefits for Your Team:

System self-monitoring reduces unplanned downtime and enables precise maintenance planning. Only truly worn parts are replaced—saving costs, increasing availability, and ensuring maximum operational safety.

Applications:

Closure inspection, Label inspection, Bottle and container inspection, Preform inspection

Support When the Inspection System Needs Help: 24/7 Service & Remote Maintenance

Even the best inspection system occasionally needs attention. If a problem arises, our global service network is at your disposal—around the clock:

• 24/7 hotline with experienced technicians
• Remote maintenance via internet connection for fast analysis and troubleshooting
• Support with software updates, calibration, or hardware checks

Benefits for Your Team:

Minimal downtime, fast assistance in critical situations, and the assurance that help is always available—worldwide.

Applications:

Closure inspection, Label inspection, Bottle and container inspection, Preform inspection

Conclusion: Maintenance with Foresight and Confidence

The maintenance team plays a key role in ensuring smooth production. Our technologies help them fulfill this responsibility efficiently and proactively—with clear data, intelligent forecasts, and rapid support in emergencies.

INTRAVIS Systems: Designed to Support.