Modernization of Software for Label Verification and Laser Marking Systems
Highlights
- Automated laser marking
- Real-time label printing and validation
- Integration with IoT devices, printers, and cameras
- Automated labeling errors detection
- Centralized management of system data via a web platform
Client
The client is a UK-based company specializing in machine vision inspection systems for manufacturing automation. They deliver solutions to identify defects, verify labels, and ensure quality control across industries such as pharmaceuticals, manufacturing, and electronics packaging.
Challenge
The client already had two systems: a desktop app for laser marking of metal parts and a label verification system. The latter supported a single printer model, had an outdated design, and lacked support for new IoT devices. To follow modern standards and technologies, the client approached SoftTeco with the goal to modernize these two solutions.
Solution
The first desktop application allows operators to input information, such as quantities of metal parts, serial numbers, start value, etc. It guides users through on-screen instructions, such as “open the machine,” “place the part,” and “close the machine.” Once completed, the app sends the corresponding commands directly to the laser marking machine for execution.
The second IoT platform is used for real-time label inspection and verification. It is connected with IoT devices, multiple printers, and high-speed cameras. Operators can configure label templates, monitor the labeling process and detect errors, like print blemishes, quality issues, or duplicates. If a defect is found, the system activates an audio/visual alert, pauses the process, and rejects the label by returning it to the printer. It connects to various printer models to ensure consistent label quality regardless of the hardware used.
The app works with a central API that allows users to store and access data, manage licenses and user accounts through the web portal, and configure system settings via the web interface. Users can interact with the solution through an intuitive 7-inch touchscreen UI that shows printer status, allows process control, and displays label quality results.
How it works
SoftTeco modernized a desktop laser marking app and IoT label verification system. First of all, we developed a communication module for the desktop system to connect it with multiple printer models, including Zebra and Printronix. As part of this module, we integrated a high-speed line scanning camera synchronized with the printer. Our team implemented camera calibration, which significantly improved image quality and validation accuracy compared to the previously limited built-in camera.
We incorporated OCV/OCR functionality using OpenCV for text and label outline recognition. This allowed us to verify the correct elements positioning (text, images, and codes) within the label boundaries and improve text recognition quality. Our developers improved a web-based platform that allows users to manage accounts, licenses, and access rights, and also provides an API to access all related data.
To ensure label marking quality, we wrote two libraries for GS1 and MIL-130 and other barcode validation systems. They allow the desktop system to detect defects, verify print quality, and identify duplicate codes. After that, our team developed a new UI for a 7″ IoT touchscreen. The new user interface has a modern, intuitive design, and supports real-time monitoring of printers and cameras.
At the client’s request, we modernized the existing desktop application migrating from WinForms and .NET Framework to WPF and .NET 8. Our specialists updated the UI by adding convenient buttons, status display showing print and validation progress, and delivered a simplified yet functional user experience. We updated app logic by adding validation and extra fields for batch settings. The solution involved transitioning to a newer version of the laser printer, working with it via the high-level API provided by the printer manufacturer.
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Results
As part of our range of IoT services, SoftTeco modernized the desktop IoT app for laser marking and real-time label inspection and verification system, added new functionalities, and support for multiple printers, high-speed cameras, and IoT devices. We implemented a responsive and modern touchscreen UI, as well as improved validation and data management via the web platform.
