What Matters Most When Purchasing a Seam Inspection System? Pt. 1 - Adaptability

Selecting a seam inspection system is rarely as straightforward as it may seem. With multiple configurations, measurement methods, and workflow considerations, asking the right questions early will lead to a better fit for your canning operation.

This is where this blog series comes into play. Over the next several posts, we will walk you through key categories of questions you should ask when evaluating a seam inspection system. In addition, answers will be provided to those questions in relation to OneVision’s seam inspection solutions as a point of reference.

To start this series, the first category is Adaptability - Will this system actually work in my facility?

Can the system integrate into our current quality and compliance workflow?

To maintain workflow efficiency, a seam inspection system must integrate seamlessly into your inspection environment. This integration allows you and your team to complete inspections in a timely manner while allowing authorized personnel quick and easy access to reports. This is exceptionally true if you plan to scale up production, meaning your inspection equipment should be able to support more advanced workflows over time.

In response, OneVision’s seam inspection systems are built with software designed to integrate into your network and workflow. For example, the SeamMate system includes an optional software upgrade, SeamManager, which provides network-wide access to inspection reports, seam images, and digital signature capabilities. Not only that, SeamMate software is also regularly updated with new features based on customer feedback to continuously improve the user experience.

How easy is it to train new operators and maintain consistency across shifts?

Having an effective training program for new operators is integral to your operation. If training is too slow or inconsistent, workflow productivity can suffer, in part due to time spent re-training both current and new operators. Additionally, poor training can lead to increased human errors during inspection, resulting in inaccurate measurements. As such, be sure to ask the manufacturer about the training program, as well as the materials and resources that are available for the equipment.

OneVision always includes system training with installation and startup of its equipment. It typically requires one full-day session and includes training for up to four people per shift. Additionally, a dedicated Training page is regularly updated with the latest resources to help both new and current operators stay aligned with best operating practices for OneVision’s seam inspection systems.

Will this system help us spot and troubleshoot seam problems fast?

Speed is a core component of adaptability. Understanding how quickly the system can perform will help you spot and troubleshoot seam problems in a timely manner. That means the system should not require excessive time to set up, capture, and analyze data inputs to deliver the results you need. In addition to speed, the system should be adaptable to external factors and changes as you scale your operations.

OneVision has continuously strived to develop inspection equipment that identifies and troubleshoots seam problems efficiently and accurately. This includes patented technology that automatically calculates seam tightness, innovative turnkey seam inspection systems, and inspection solutions designed for a wide range of applications.

A strong example is the SeamMate system’s video module. Designed to measure both seam thickness and project a live camera view of the slotted can seam, the video module can capture, analyze, and present seam measurements with just a click of a button. It also requires minimal set up before you can start measuring. Regular calibration is recommended to maintain accuracy, and the calibration process itself is quick and easy to perform.

Does the system work across different cans, ends, and products?

Having a system that works across different cans and products is both a time- and cost- saving measure. You shouldn’t have to invest in multiple tools that each perform a single function when those capabilities can be incorporated into one system to reduce downtime, especially if you plan to scale your production.

OneVision’s inspection systems can function across different cans and products, but to an extent. It often depends on whether your cans are for food or beverage. For example, our Manual Seam Saw offers two configurations: the Model 550 is designed for cutting food cans, while the Model 555 is ideal for cutting beverage cans. For this reason, when considering inspection system solutions, be sure to identify which model is best suited for your specific application.

In Conclusion

Adaptability is a core foundation of any effective seam inspection system. To reduce potential bottlenecks, measurement inconsistencies, and inaccurate results, it’s important to invest in an inspection system that can adapt within your operation. As you research and evaluate your options, make sure to ask the manufacturer questions like those outlined in this article so you make the right investment.

In the next article, we’ll explore Usability - Is the system easy to live with? as another key category to consider when purchasing a seam inspection system.

Which Seam Saw is Right for your Operation?

Clean, perpendicular slotting is a critical step in double seam inspection. If the cut distorts the seam or shifts the centerline, measurement accuracy can be compromised. The right seam saw ensures clean cuts, protects seam integrity, and supports reliable inspection results.

At OneVision, we offer three cutting options designed for different inspection environments and production needs. Let’s take a closer look at each one to help you determine which saw is the best fit for your operation.

Mini Saw

The Mini Saw is the most portable cutting solution in our lineup. Sold as part of the Portable Beverage System, it delivers quick, clean slotting on the go. The battery-powered saw offers a flexible, modern approach to cutting beverage can seams, making it ideal for line-side inspections and mobile quality checks.

Mini Saw

Featuring a carry handle, the Mini Saw is designed for portability. Weighing approximately 14 lbs with its battery installed, it’s easy to transport and take to the line for quick cutting operations.

The saw is anodized for added durability and corrosion resistance. The anodized finish holds up well in harsh production environments while giving the unit a clean, professional look.

Swappable seam guides are available for beverage cans sized 200 through 206. Manufactured using 3D printing technology, the guides can be quickly changed to accommodate different can sizes during slotting.

The Mini Saw is currently designed for aluminum beverage cans only. Due to the blade type and motor configuration, it is not intended for steel applications. A steel-capable model is currently in development, with an expected release later this year. While the Mini Saw is commonly sold as part of the Portable Beverage System, it can also be purchased separately if needed.

>> If you need to bring the saw to the can rather than the can to the saw, the Mini Saw is a great solution for your operation. <<

Manual Seam Saw

Designed for dedicated inspection stations, the Manual Seam Saw delivers consistent, repeatable cuts and dependable performance in high-volume environments.

Manual Seam Saw

Two models are available to accommodate various can types. The Model 550 Manual Seam Saw slots steel cans sized 211 to 602 without part changes. The Model 555 Manual Seam Saw is designed specifically for cutting aluminum beverage cans.

The saw is easy to use, maintain, and service. Its tilt-table design makes cutting can seams quick, consistent and accurate. Built with longevity in mind, the unit can be serviced directly, including blade changes and routine parts replacements. It is well suited for high-volume production environments.

It produces precise cuts with a perpendicular centerline. Equipped with 30 teeth-per-inch blades for steel cans and 24 teeth-per-inch blades for aluminum cans, the saw is engineered to angle the cut properly, ensuring clean slots without seam distortion.

Powered by a rugged gear motor. Due to operating noise levels, operators are required to wear hearing protection during use.

>> If you need dependable, repeatable cuts in a high-volume environment, the Manual Seam Saw is a proven solution for your operation. <<

Automatic Seam Saw

For facilities seeking reduced noise and a more automated cutting process, the Automatic Seam Saw builds on the same cutting precision in a fully enclosed cabinet.

Automatic Seam Saw

Easy to Use. The self-contained design minimizes operating noise, making the Auto Saw suitable for a wide range of work environments, including laboratories, without the need for hearing protection.

Fully enclosed unit. The operator loads the can, closes the lid, and the cutting cycle starts automatically. Once the first cut is made, the operator opens the lid, rotates the can, and repeats the process. The aluminum lid shields the operator from potential debris, while the cabinet houses both the operating system and saw blades within a controlled environment.

Accommodates can sizes 200 to 603, including steel, beverage and composite cans. With dedicated seam guides designed for each can size, the saw produces slots ready for inspection. The Automatic Seam Saw streamlines and standardizes the cutting process.

Air-powered operation. An external air supply is required to support the pressurized system.

>> If your operation values enclosed cutting, reduced noise, and a more automated workflow, the Automatic Seam Saw is a strong fit for your operation. <<

So, Which OneVision Seam Saw is Right for Your Company?

Choosing the right seam saw requires understanding how and where you will perform seam inspections, whether it will be on the production floor, in a lab setting, or directly at the line. As such, consider the primary aspects of each saw:

Mini Saw: Mobility, quick checks, line-side inspections

Manual Seam Saw: High-volume use, maintenance-friendly, dedicated inspection stations

Automatic Seam Saw: Enclosed cutting, reduced noise, automated workflow

Each solution integrates with OneVision’s seam inspection systems to support accurate measurement and reporting.

Ultimately, your seam saw should align with your workflow, production volume, and inspection environment. When properly matched to your operation, the right seam saw will ensure repeatable, reliable inspection results—helping you maintain can seam quality.

What is Can Seam Inspection?

If you package food, beverage, or oil into cans, it is crucial to create an airtight or hermetic seal with your can seam to protect your product. Follow-up and inspection of those seams is just as important to ensure your product maintains its quality and to keep unwanted substances from passing in or out.

Let’s break down the basics below.

What is a Hermetic Can seam?

A hermetic can seam, or double seam, is formed by interlocking the edges of the can end and the can body. This is done by a can seamer through a two-stage operation. The first operation involves curling the body of the can into the can end to create a cover hook. The second operation tightens and flattens the seam together to create the double seam. A sealing compound is also applied to keep the seam together and maintain its airtight seal. This process creates the airtight seals needed to contain and preserve the product inside the can.

First Operation

Second Operation

The Can Seam Inspection Process

Can Seam Inspection is the formal procedure for inspecting the double seam to ensure canned products are properly sealed to preserve the product’s quality and protect the product during distribution. This process involves measuring external and internal seam dimensions as well as checking for any possible seam defects.
Specifically, the inspection aims to verify four essential requirements of a quality double seam:

1. Correct Tightness: The seam needs to be sufficiently tight to allow the sealing compound to hold under compression.

2. Correct Body Hook & Cover Hook Length: The length of the cover hook and the body hook are measured to confirm they are within proper tolerances.

3. Correct Overlap: There must be sufficient overlap of the cover and body hooks to ensure an airtight seam.

4. Other Critical Defects: Seam needs to be free of distortions such as false seams, vees, sprung seams, or seam bumps.

To evaluate these four requirements, several measurements need to be taken:

• Countersink Depth
• Seam Thickness
• Body Hook
• Cover Hook
• Overlap
• Seam Height
• % Overlap
• % Body Hook Butting
• Seam Tightness

External Double Seam Dimensions

Internal Double Seam Dimensions

These measurements need to be compared to the can manufacturer’s double seam specifications to ensure they fit within safety parameters. If they do, you can be assured that your seams will perform well during the packaging and distribution of your products.  If they don’t, you now have the data needed to inspect and adjust your can seamer appropriately.

Tools for Conducting Can Seam Inspection

Conducting can seam inspections requires specific tools to collect critical measurements during the inspection.

A countersink gauge measures the countersink depth.

Manual tools such as a micrometer and calipers measure seam thickness and seam height.

Seam saws make vertical cuts through the double seam in order to view the internal characteristics of the seam.

Video imaging systems show the external and internal double seam measurements such as seam height, seam thickness, body hook, overlap, and cover hook.

Seam strippers or handheld manual tools “tear down” a can (remove the cover hook) to evaluate seam tightness and seam defects.  You can learn more about the step-by-step process of a manual teardown here.  Seam Strippers perform this task more safely and efficiently.

In Conclusion

Hermetic double seams are formed when the can body and the can lid are folded together properly to seal the can and prevent leaks and contamination.  The critical step of can seam inspection involves taking specific measurements to ensure double seam quality.  Both manual and automated tools can be used to inspect can seams.

OneVision specializes in can seam inspection equipment and delivers comprehensive, affordable solutions that help businesses ensure shelf stable products and meet regulatory requirements.

3 Myths About Can Seamers and Double Seam Inspection

Within every industry, there are misconceptions, aka myths, that need to be addressed to ensure best practices. Due to its complexity, seaming and can seam inspection are often misunderstood, leading to avoidable quality issues. Here we will address 3 myths to help you elevate and improve your canning processes and double seam integrity.

Myth 1: All Cans & Lids are the same

Two cans may both be labeled as size 200, but that doesn’t guarantee they are identical. Often, different manufacturers require unique tooling to achieve a proper, airtight seal. Due to manufacturer variations, cans of the same size can have different seam measurement specifications. This is especially true when pairing cans and lids from different manufacturers.

This is why conducting can seam inspections is crucial to the canning process. Comprehensive inspections will provide the confidence that your seaming equipment is creating seams that meet hermetic standards. While visual inspections can typically identify most defects, conducting comprehensive, destructive double seam inspections will ensure defects that may be missed by the naked eye are caught.

Myth 2: Once a Seamer is set up, it stays in spec indefinitely

Seamer maintenance can easily be overlooked or neglected. However, like any machine, can seamers require regular maintenance to stay within specification. Seamers have multiple moving parts that make repeated metal-to-metal contact. Over time, this repeated contact leads to wear that can compromise seam quality. Proper, regularly scheduled maintenance of your can seamer will minimize potential risks to your product. Always consult the manufacturer’s manual for detailed seamer maintenance guidelines. Additionally, third-party providers such as our partners at RSS Maclin offer specialized training, maintenance, and support services.

Integrating double seam inspections within your quality control program will give you added information to predict and pinpoint areas of concern. By identifying whether an issue stems from work or misaligned equipment, you can take proactive action before it affects production, protecting both your product and your reputation.

Myth 3: Only Large Companies can afford double seam technology

This is one of the most persistent misconceptions in the industry. Today, double seam technology is more affordable and accessible than ever. The belief that the canning process is overly complex or prohibitively expensive simply isn’t true. A small canning line with low automation can start at under $30,000. In addition, modern seamers are built with minimal maintenance requirements, are designed to be user-friendly, and deliver long-term cost savings for businesses of any size.

This also applies to can seam inspection technology. OneVision offers options like the Manual Teardown Kit, the Portable Beverage System, and various SeamMate System bundles which are designed to fit budgets of all sizes. With over 30 years of experience and lifetime technical assistance included with OneVision systems, you can rest assured that investing in can seam inspection equipment is a smart and affordable decision.

The Bottom Line

Misconceptions about can seamers and seam inspection technology can lead to poor decisions that affect product quality. Whether your business is just starting to can, or you’re experiencing growth and need to expand your quality control program, now is the time to consider investing in can seam inspection solutions. Also, remember to know your can and lid manufacturer specifications and follow a regular seamer maintenance program.

Seam Inspection Solutions: Which One's Right for You?

Inspecting can double seams is an essential step during the packaging process to ensure your product is safe and ready for the market. With so many seam inspection solutions to choose from, which one is the right fit for your company?

Operators can use manual tools to check seam tightness, countersink, thickness and height.  Another option that moves beyond manual tools is a more reliable method of visual inspection using a system that provides consistent double-seam checks but without automated measurements.  Companies that require advanced measurement capabilities can use a comprehensive inspection system with predictive and preventive intelligence.

Without adequate information, the selection process can be a daunting task. Your choice depends on your company’s goals and needs, factoring in your requirements for inspection, measurement and reporting as well as your budget. 

Manual Teardowns

At a minimum, beverage canners should routinely perform manual can teardowns and use proper tools to check critical seam measurements including tightness, countersink, thickness, and height. It’s recommended to take these measurements at the start, middle, and end of each production run.

Manual Teardown Kit

To manually inspect seams, operators will need tin snips, a utility knife, or a manual can cutter to carefully separate the can lid from the body. It’s important to avoid crushing or deforming the seam during cutting and to wear safety gloves to prevent injury. Once separated, handheld measuring tools are used to record key seam measurements.

What measurement tools are required?

OneVision’s Manual Double Seam Teardown Kit includes the necessary tools for conducting manual seam checks: a countersink gauge, micrometer, calipers, and machinist ruler.

Manual Teardown Kits are affordable.  This is a great choice for companies just starting out or working with a tight budget.  These kits contain the tools needed to inspect and measure seams, and they offer a good value for the price.

Multiple tools can be utilized with various types of cans. The tools in the kit can be used to inspect the double seams on both small and large cans.  The countersink gauge is customizable based on can diameter and lid type.  The micrometer and calipers confirm seam measurements are within specification.

Everything is contained in one protective case. The case is an ideal size to fit all the tools but isn’t overly bulky or heavy.  Protective foam padding safeguards all the tools during shipment and provides storage between uses.

However, this kit lacks automation features compared to more advanced inspection solutions. Operators need to calculate double seam measurements by hand.  And, prior to utilizing this kit, operators must manually tear down their cans which can be difficult and time-consuming.

Visual Seam Inspection

Visual seam inspection provides a faster, more reliable, and more accurate way to assess critical double seam measurements compared to manual teardowns. Optical measurement systems speed up the process, reduce inspector error, and detect subtle seam defects such as wrinkles, droops, or false seams that might easily be overlooked during manual checks.

Depending on the size of your operation and budget, OneVision offers a range of visual inspection systems equipped with high-precision video microscopes.

Portable Beverage System

The Portable Beverage System is another solution that offers brand-new technological innovation for can seam inspection.  First, the compact saw makes slots in the cans and then the high-precision microscope combined with a viewing screen allows the technician to visually inspect and measure the seam.

Portable Beverage System

The compact Mini Saw slots 200, 202 and 206 beverage cans. The Mini Saw quickly and effectively cuts beverage cans for conducting visual inspection with ease. Its high-quality blades last for 2-3,000 cuts before needing replacement.

The QuickViewer™ allows seam images to be captured and exported to a USB Drive for easy transfer of data. The built-in touchscreen lets the operator view and save the seam in real-time.  Using the provided flexible ruler, on-screen measurements can be taken to quickly calculate body hook, cover hook, overlap, seam height and seam thickness.

The 2-piece system is housed in a sturdy case so it’s truly portable.  The Mini Saw and QuickViewer are protected with foam padding, and the entire weight with case is only 25 pounds.  With this grab and go system, visual inspections can be conducted right at the can line.

While the Portable Beverage System is tremendously useful since it offers unique capabilities for seam inspection, it does not feature automated measurement software to measure and label the parts of the can seam. The Portable Beverage System only grants visual inspection capabilities with the option to calculate your own measurements.

SeamMate® System

The best-selling, most advanced solution for can seam inspection is the SeamMate System which offers beverage canners a highly-automated approach to inspecting double seams using patented technology.

While the SeamMate system is the most powerful turnkey system in the industry for inspecting double seams, it does come with a higher price tag compared to the Portable Beverage System and Manual Takedown Kit.

SeamMate System

The SeamMate’s Video Module combines multiple inspection processes into one unit. Along with a high-precision microscope for viewing the can seam, the Video Module also includes a built-in thickness gauge and a hand-held countersink gauge for calculating all can specifications and measurements.

As part of the patented technology within SeamMate, this system’s software automatically analyzes the can seam to capture measurements and calculate seam tightness. This information can then be stored in a database integrated into your network for easy transfer and analysis.

The complementary Manual Seam Saw produces fast, clean cuts on beverage cans.  The tab bender opens the slot for viewing on the Video Module, making the inspection process quick and easy.

So, Which OneVision Inspection System is Right for Your Company?

The Manual Double Seam Teardown Kit and the Portable Beverage System are highly useful solutions to consider. The Teardown Kit provides hand tools for seam inspection.  The compact and budget-friendly Portable Beverage System adds the capability of slotting cans, viewing seams on a convenient touchscreen, and saving images to a flash drive. 

For companies that require automated measurements and reporting capabilities, the SeamMate System does it all!  It is a fast, accurate, user-friendly seam inspection system.

After considering your company’s needs, requirements, and resources, select the seam inspection solution that’s right for you to ensure double seam quality.   This critical step will help you be certain that your company’s products are packaged safely for your consumers to enjoy.

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Seam Inspection System Comparison Chart