AI Computer Vision in the FMCG Manufacturing

Shubham Darwatkar
Aug 8
2 min read

Speed Without Sacrificing Accuracy

The FMCG sector is about scale and speed. Millions of bottles, packets, and cans roll off production lines every day. At that scale, even a 0.5% error rate can flood shelves with defective products hurting both sales and brand trust.

The problem? Manual checks just can’t keep up. That’s why forward-thinking brands are opting for AI Computer Vision in the FMCG Manufacturing deploying Eaglai Detect.

Two workers in turquoise uniforms and hairnets pack boxes in a sterile factory setting. Machinery surrounds them on a blue floor. — Defect Detection in FMCG

The Challenge in the FMCG Industry

One high-volume beverage manufacturer faced:

Labels misaligned or fading, hurting brand presentation
Packaging damage going unnoticed at speeds of ~200 units per minute
Foreign objects slipping past manual checks
Over 50,000 defective units reaching shelves every month

Annual returns and complaints costing $2–3 million

Implementing AI in FMCG Manufacturing: Eaglai Detect

The facility integrated Eaglai Detect along its packaging conveyors. Key components included:

High-frame-rate industrial cameras (up to 1,000 FPS)
Deep learning models trained to catch:
- Label orientation errors and color mismatches
- Cap seal defects and missing tamper rings
- Cracks, spills, or deformed bottles
- Barcode and expiry code errors
Real-time rejection systems integrated with ERP for traceability

Factory worker in black gloves handles yellow bottles on an assembly line. Background shows machinery and more bottles. Industrial setting. — AI in FMCG Manufacturing

How It Worked | Operational Flow of the AI System

Multi-angle cameras captured each unit at full line speed
AI classified products in real time, ejecting defective ones instantly
Operators tracked live defect stats through a user-friendly interface

The Results

The transformation was striking:

Detection accuracy rose to ~99.3% (from ~85%)
Line speeds maintained at 400–450 units per minute without compromise
Customer complaints dropped from ~8,000 per month to under 600
Returns and compensation costs cut by over 70%
Payback period: less than 10 months

The Takeaway

For FMCG brands, Eaglai Detect proves that speed and quality can go hand in hand - protecting brand trust while keeping shelves stocked. The system’s real-time feedback loops allow immediate self-correction, reducing downtime.