Catch parison defects before it's too late

Mold changes, process drift, and heater band degradation can introduce variation into the parison. When there's an issue, you often won't know until there is increased scrap or an experienced operator reveals it, leaving you with lost material, machine time, and throughput.

Eigen's AI thermal inspection system captures a full thermal profile of every parison as it forms, analyzes it in under one second, and tells your team exactly when something changes—before bad parts are made.

What Eigen’s thermal AI can monitor

1. Shape and integrity
Detects sagging, stretching, asymmetry, and swing misalignment. The fastest way to confirm setup is good after a mold change.

2. Parison length
Catches premature cutoff and mold mismatch shot-to-shot.

3. Thermal profile
Maps temperature gradients top to bottom, identifying cold spots and uneven cooling that cause wall thickness variation.

4. Spill and die condition
Flags overflow near the die head as an early signal of die wear or backpressure issues.

5. Severity-based alarms
Configurable thresholds drive HMI alerts and PLC signals so operators get actionable information, not noise.

How the system works

Multiple thermal cameras provide a full view of the parison, with images triggered either at the end of formation or continuously as it extrudes. 

Within Eigen's software, trained AI models analyze these images for shape and temperature uniformity, alerting operators to deviations in real time.

Where thermal AI pays for itself

Mold changeover is where most blow molding scrap is generated. Enable your setup team with real-time feedback on whether the parison profile matches the target.

Large-format containers (e.g., IBCs, drums, jerry cans) carry significant resin cost per part. Continuous monitoring catches issues that would otherwise become expensive scrap.

Multi-line and multi-plant operations benefit from OneView Cloud, which consolidates inspection data across machines so your engineering team can compare performance and standardize processes.

Frequently asked questions

We already have thermal cameras. How is this different?

A camera gives you an image often with user defined thresholds. Eigen gives you automated analysis of every shot with trend tracking, severity classification, and control system integration. The difference is between watching for what’s known and having a system that tells you when to act on the unknown.

How long does it take to deploy the system?

With deep experience in blow molding, initial value can be seen within days. During commissioning, we optimize the solution to your machine, mold, and material with data streaming live on the HMI. It’s then on to model refinement for production acceptance.

How does the system adapt to material changes?

AI doesn't just see heat; it sees patterns. By training on thousands of cycles, the system recognizes the thermal signature of a defect before the part or bottle is formed. This reduces the number of false alerts that could otherwise be induced by material changes.

See the system work on your line

Reach out to our team to learn more and to schedule an on-site demo. During the demo, our engineers set up the system on your line so you can see the results in real-time.