Capture
Receive the fail result and identify the product associated with that decision.
Detect, track, reject and prove
Fail-safe reject verification systems.
Independent confirmation closes the gap between an inspection fail signal and evidence that the correct product was removed.
Direct answer
What is reject verification?
Reject verification is an independent check that the product identified as failed reached the reject area. The controls know which product should be removed, monitor the reject event and expect a confirmation within a defined window. If proof is missing, the system can alarm, stop the line and require an authorised investigation.
Verification does not replace a sound reject mechanism; it proves that the complete sequence achieved its intended result.
Closed-loop sequence
Track
Maintain product position using timing, sensors or encoder-based distance tracking.
Reject
Operate the selected actuator inside the correct product window.
Confirm
Receive independent evidence that the failed product entered the secure reject route.
Conditions that can be supervised
Monitor the reasons a reject could fail.
Reject confirmation
A sensor expects the rejected product or its passage into the reject chute or bin.
Actuator position
Feedback confirms that a pusher, flap or diverter completed the commanded movement.
Low air pressure
Pneumatic pressure below the agreed threshold can prevent operation and initiate a line stop.
Reject bin full
Bin-level sensing prevents accepted production continuing when secure capacity is unavailable.
Access and security
Door or bin access can be monitored so rejected product cannot re-enter the good stream unnoticed.
Product backup
Downstream accumulation and blocked-product conditions can be detected before tracking becomes unreliable.
What should happen when verification is missing?
The response is defined by the customer's risk assessment and quality procedure. Typical actions include stopping the conveyor, raising audible and visual alarms, recording the event, holding subsequent product and requiring an authorised reset after the affected product window has been investigated.
Challenge testing
Commissioning should prove normal rejection and deliberately test monitored faults such as a missing confirmation, low air pressure, full bin or opened access point. The agreed tests and recovery steps should be understandable to production and quality personnel.
Common questions
Verification and fault handling.
The final architecture must match the inspection risk and production process.
Is a reject confirmation sensor the same as an actuator sensor?+
No. An actuator sensor may prove that the mechanism moved, while a separate product sensor can confirm that the failed product reached the reject route.
Can verification be added to an existing conveyor?+
Often, yes. Feasibility depends on product spacing, sensor access, conveyor layout, control interfaces and the available reject zone.
Can reject events be sent to a line PLC?+
Yes, where interfaces are available and agreed. Reject, confirmation, fault and system-ready signals can be incorporated into the project scope.