Essity Packaging Defect Detection: How DefectGuard is Reducing Waste and Boosting Accuracy

In the packaging industry, even the smallest defect can have a significant impact — from damaged brand reputation to costly product recalls. For global hygiene and health company Essity, ensuring packaging quality is non-negotiable.

Their products must reach customers in perfect condition, whether it’s tissue paper, diapers, or healthcare supplies. However, manual inspection methods were proving inconsistent, slow, and unable to keep pace with the high-speed production lines.

To address this challenge, Essity turned to Brightpoint AI’s DefectGuard — an advanced AI-powered defect detection system designed to identify packaging defects in real-time, reduce waste, and ensure every product meets quality standards.

The Packaging Challenge

In high-volume manufacturing, packaging defects can occur due to:

• Sealing issues — incomplete or weak seals leading to compromised product integrity.

• Wrinkles and folds — affecting packaging appearance and potentially damaging the seal.

• Misaligned labels — impacting brand presentation and traceability.

• Tears or punctures — compromising hygiene and safety standards.

For a company like Essity, which operates on a global scale, these defects not only result in material wastage but also affect operational efficiency and customer trust. Manual inspections were insufficient, as human inspectors could miss subtle but critical defects at high production speeds.

Introducing DefectGuard

DefectGuard is Brightpoint AI’s cutting-edge computer vision solution, specifically built to detect defects in manufacturing environments with sub-second accuracy.

For Essity’s packaging lines, DefectGuard was configured to:

1.  Capture high-resolution images of each packaged product at production speed.

2.  Analyze the seal quality using AI models trained on thousands of defect and non-defect samples.

3.  Flag defective products instantly so they can be removed from the production flow before reaching the market.

4.  Provide analytics for production managers to identify recurring issues and optimize processes.

How It Works

1. Real-Time Imaging – High-speed industrial cameras capture every package in motion.

2.  AI-Powered Analysis – DefectGuard’s deep learning algorithms identify defects such as poor seals, wrinkles, or foreign particles with 99% accuracy.

3. Automated Sorting – The system triggers removal mechanisms for defective products without slowing production.

4.  Continuous Learning – The AI model improves over time, adapting to new defect types and changing production conditions.

Key Benefits for Essity

After implementing DefectGuard, Essity experienced:

• Waste Reduction – Significant drop in defective packaging waste, lowering material costs.

• Improved Accuracy – Consistent detection of even minor sealing defects that human inspection often missed.

• Operational Efficiency – Automated inspection at full production speed without bottlenecks.

• Data-Driven Insights – Quality reports and trend analysis to prevent defects before they occur.

• Brand Protection – Ensuring only flawless products reach customers, reinforcing Essity’s quality commitment.

Results Achieved

Within months of deployment, Essity reported:

• 30% reduction in packaging waste

• Near-elimination of sealing defects in shipped products

• Improved throughput with zero production slowdowns

• Better visibility into root causes of defects, enabling preventive maintenance

Why DefectGuard Stands Out

Unlike generic vision inspection systems, DefectGuard is designed with manufacturing-specific intelligence:

• Custom AI Models – Trained on industry-specific defect types.

• Scalability – Works seamlessly across multiple production lines and plants.

• Integration-Ready – Connects with MES/ERP systems for unified quality tracking.

• Minimal False Positives – Reduces unnecessary rejections and optimizes yield.

Conclusion

The partnership between Essity and Brightpoint AI demonstrates how AI-powered defect detection is reshaping the packaging industry. With DefectGuard, Essity has moved from reactive quality control to proactive defect prevention — achieving higher efficiency, reduced waste, and uncompromised product quality.

For packaging-intensive industries, this case is a clear reminder: when speed meets precision through AI, quality is no longer a trade-off — it’s a guarantee.