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Industrial FilmCustomer story

Solving a 30-year defect, and saving millions.

Blistering had resisted every attempt to explain it since before most of the plant was hired. Nobody had ever measured it.

A machine-vision frame of the industrial film, with teal boxes drawn around each blister the model detected.
Every blister the model found, boxed. Severity has to be measurable before a cause can be argued.

One of your core products has blistered for 30 years.

Picture this. You are a billion-dollar industrial film manufacturer. One of your core products has suffered from blistering for 30 years, resisting every attempt to explain or eliminate it.

But the defect drives scrap rates as high as 10%.

Your teams can see the blistering, but they cannot measure it consistently or connect it to a cause.

Without empirical defect data, every investigation ends with another theory instead of an answer.

So you turn to Shelfmark.

AI-powered inspection is deployed directly on the line to detect blistering in real time and quantify its severity for the first time. That creates the empirical defect data your team needs to connect what is appearing in the product with what changed in production.

Now the pattern is clear.

Shelfmark data traces the blistering to specific batches of supplier material, giving the supplier the evidence needed to find and resolve the root cause. A problem that resisted investigation for three decades becomes visible, measurable and preventable, saving your business millions in scrap and rework.

Technical summary

The manufacturer used AI visual inspection to quantify a 30-year blistering defect for the first time, and the data traced it to specific batches of supplier material.

Industrial FilmScaling AI inspection across 100+ SKUs.One inspection model across 100+ SKUs, with no reference set per SKU.Industrial FilmA mirror at 400 feet per minute. Fully inspected.Metallic film at 400 ft/min, with the imaging built around the surface.

Some defects are not mysteries. They are just unmeasured.

Talk to a
Shelfmark expert.

See if it’s a fit.
In 30 minutes you’ll know whether we can catch your defects, on your substrate, and your line speed.
See what’s possible.
We can show you the real thing. A line with every defect caught automatically; fewer escapes, less rework, and capacity you didn’t know you had.
See if we are full of shit.
We are a young company doing things that have never been done before. We own that, and we will answer any questions you have.