Automation isn’t just a convenience—it’s a necessity. For food, beverage, and consumer packaged goods (CPG) producers, the ability to inspect, sort, and verify products in real time is critical to driving efficiency, ensuring product quality, and safeguarding brand reputation. Enter 3D machine vision—a game-changing technology reshaping the way manufacturers approach quality control and logistics.

Why 3D Machine Vision?

Traditional quality control often relies on random sampling—a method that inspects a small subset of products and assumes the entire batch meets specifications. That approach leaves room for error and missed defects. In contrast, 3D machine vision enables 100% in-line inspection, offering unmatched accuracy and consistency.

These systems can:

• Eliminate manual inspection errors
• Monitor product compliance in real time
• Collect operational data for better process control

Enhance customer satisfaction through consistently high quality

Smarter Inspection Across Food, Beverage & CPG

3D machine vision tools, like Zebra’s AltiZ 3D laser profilers, go beyond what traditional 2D systems can see. They detect product volume, surface defects, dimensions, and fill levels—capabilities crucial for maintaining the integrity of complex packaging lines.

Common applications in food production include:

• Verifying slice count and intactness in prepackaged cheese
• Sorting meat or fish portions by size for optimized packaging
• Ensuring uniform chocolate application on wafers
• Detecting broken cookies or wafers before packaging

In beverage and CPG environments, 3D vision is used to:

• Check cap alignment and seal integrity on bottles
• Measure fill levels in jars and containers
• Detect missing or damaged items in kits and cases

Verify that products are properly packed for shipment

Streamlining Logistics and Warehouse Operations

3D machine vision isn’t limited to production lines. It also powers logistics efficiency by automating dimensional inspection and sortation. Laser profilers measure object size, shape, and placement on conveyor belts, feeding data to robotic palletizers for precise loading.

Use cases include:

• Sorting parcels by size for shipping
• Confirming box placement and alignment
• Reducing waste by identifying damaged containers before filling

The Power of 3D Line Profiling

At the core of Zebra’s 3D solution is line profiling via laser triangulation. This method creates detailed surface maps in millimeters, capturing width, height, depth, and volume. Unlike basic checkweighers, 3D profilers detect hidden defects that weight alone can’t reveal—such as a missing chocolate layer or a cracked seal.

Dual-camera profilers like Zebra’s AltiZ provide a complete view, minimizing the effects of shadows and lighting inconsistencies while capturing even the finest details.

Easy Integration, Immediate ROI

Zebra’s 3D profilers are designed for simple setup with just four required connections. Using the Aurora Design Assistant™, manufacturers can deploy ready-to-use inspection templates or build custom vision applications with ease.

Capabilities include:

• Pass/fail product routing via PLC
• OEE and ERP system data integration
• Customizable inspection zones and resolutions

Real-world unit output for accurate reporting and compliance

Build a Smarter, Safer, and More Scalable Operation

As labor shortages continue and performance standards rise, 3D machine vision is emerging as a mission-critical technology across the packaging and logistics chain. From ensuring every product meets exacting quality standards to empowering smart sortation and fulfillment, Zebra’s 3D vision tools are helping manufacturers unlock new efficiencies—and new opportunities. Explore the range of Zebra products here.