SUPERB AI.

Overview

Quality control is a critical factor in determining product reliability and brand value in the food and beverage industry. For companies exporting overseas, meeting stringent quality standards is essential for entering and sustaining a presence in global markets. Pocheon Ildong Makgeolli, a well-recognized Korean brand in the traditional liquor market, has continuously pursued automation and advancement of its production processes to ensure consistent product quality for both domestic and international customers.

However, the existing manual inspection process had limitations in identifying issues such as defective lids, misprinted labels, and deviations in content volume. These challenges were particularly problematic when exporting to Japan, where trust in quality is a critical factor. To overcome these issues, Pocheon Ildong Makgeolli partnered with Superb AI to implement an AI-powered automated quality control system.

Challenge: How to Build an Accurate Quality Control System for Fast-Moving Production Lines amid Limited Data Availability

Pocheon Ildong Makgeolli faced three primary quality control challenges:

1. Lid Defects:

Damage, deformation, or improper sealing of bottle lids during the production process, compromising product quality

2. Label Issues:

Ink smudging during expiration date printing, making it difficult for consumers to read essential product information

3. Content Volume Variations:

Deviation from standard fill levels, a particularly critical issue for exports to Japan where non-compliance could damage brand credibility and result in regulatory violations.

“Content volume variation is especially critical when it comes to exporting to Japan. We’ve had issues in the past, and given Japan’s strict quality standards, we knew our production system needed to be significantly upgraded.” — Eunsoon Kim, Executive Director, Pocheon Ildong Makgeolli

One of the greatest challenges in implementing the AI system was data acquisition. The quality control system had to operate on a fast-moving, vibration-prone conveyor belt, while accurately capturing images of caps and labels, inferring defects in real time, and calculating content volume on the fly to remove non-compliant products from the line.

Solution: Implement an AI-Powered Quality Inspection System with Tailored Hardware Configuration and Efficient Data Management

To address Pocheon Ildong Makgeolli’s quality control challenges, Superb AI implemented a comprehensive approach encompassing both hardware and software optimization.

1. Optimized Camera Setup and Sensor Calibration

Three cameras were strategically installed along the production line to capture product images from multiple angles. Sensors were finely calibrated to ensure stable data acquisition, even on the vibration-prone conveyor belt.

2. Efficient Data Collection and Labeling Process

“We captured as many samples from underrepresented classes as possible during our data collection sessions. Using Superb Platform’s curation tools, we were able to quickly identify defect data and label them efficiently. This significantly improved the overall efficiency of model training.” — Hansung Park, Manager at Superb AI

3. Model Tailored to Real-World Conditions

Although data augmentation was initially considered, the expert team at Superb AI determined that it would not fully capture the specific characteristics of the actual production environment. As a result, they focused on training the model using real data to maximize accuracy in the real-world setting.

4. Integrated Solution Combining Hardware and Software

This project was executed as a fully integrated system—combining hardware and software—to detect and remove defective products in real time. Cameras and sensors were installed on the production line, while the AI model rapidly processed live data to trigger immediate quality control actions. While Pocheon Ildong Makgeolli handled hardware procurement and installation, Superb AI’s experienced specialists provided consultation on hardware setup and supported system integration and end-to-end operations. This minimized the client’s technical burden while ensuring a successful deployment.

5. Automated Defect Ejection System

An automated defect ejection system was implemented, enabling the hardware to immediately remove defective products from the production line upon detection by the AI model. This was a particularly favored feature by the client, as it allowed for instant quality control without any human intervention.

The AI model was refined over a period of three months—from the initial prototype to the final version—through additional testing and reshooting of data to accommodate environmental variables in the hardware setup.

Benefit: Driving Business Value Through Labor Optimization and Enhanced Export Product Credibility

By implementing an AI-powered quality control system, Pocheon Makgeolli achieved the following key benefits:

1. Maximized Inspection Efficiency

The manual inspection process, previously handled by three workers, was replaced by the AI system—significantly reducing inspection time and labor costs. Human resources were reallocated to secondary inspection tasks and other higher-value activities.

2. Real-Time Quality Control

Images were captured in sync with the speed of bottles moving along the conveyor belt, and inference results were delivered to the server within 2–3 seconds. This high-speed inference enabled a real-time quality control workflow.

3. Precise Management of Content Volume

To ensure accurate measurement of liquid levels even in a vibration-heavy conveyor environment, a median-value calculation algorithm was applied. This effectively resolved content volume variation issues, which could otherwise cause problems when exporting to Japan.

4. Improved Accuracy Through a Multi-Stage Inspection System

The system was designed to perform multiple rounds of inspection using three cameras at different stages. If any one of the cameras detected a defect, the product was automatically ejected—minimizing the chance of defective items being shipped.

Conclusion: A Successful Fusion of AI Technology and Traditional Industry

Pocheon Ildong Makgeolli’s adoption of an AI-powered quality control system illustrates how traditional industries can successfully embrace cutting-edge technology. Far beyond a simple technology adoption, this project became a catalyst for strategic transformation—boosting productivity, improving quality, and strengthening the brand’s global competitiveness.

Superb AI will continue to deliver innovative solutions that help industrial partners like Pocheon Ildong Makgeolli boost productivity and improve quality through the power of AI.