AI Fabric Inspection: The 16 Most Common Questions
Every mill that looks at AI fabric inspection for the first time asks roughly the same questions: How does it work? Which defects does it detect? Will it fit my machine? What happens to my operators? What does it cost? In this post we have collected the sixteen questions we hear most often in sales and technical meetings, with answers that mean something on your line — without the marketing language.
We have grouped them under five headings: what the system does, accuracy and speed, installation and fit, operators and daily use, and data and cost. At the end of many answers you will find a link to a post that covers the topic in more detail. If your question is not here, see the short FAQ at the end of the post and the contact link.
What does the system do?
1. What exactly does AI fabric inspection do?
It continuously scans the fabric passing through the inspection machine along the full length of the roll, detects surface defects in real time and records each one with its roll, position and type. The system takes over the scanning that the operator does by eye in manual inspection; the operator manages the system, reviews detections and approves the final quality decision.
The difference is not "seeing" the defect — it is turning the defect into evidence. In manual inspection a defect may be noticed but is often not recorded systematically; when a buyer claim comes in, the question "was that defect really there?" is left to memory. With AI-supported inspection, every roll has a defect map and a report. We describe the steps of the process here: What Are the Stages of the Fabric Quality Control Process?
2. How does the system work — what does it change on my line?
A scanning unit mounted on the inspection machine images the fabric surface; the AI recognises, locates and classifies defects in that image. The result appears as a live defect map on the screen in front of the operator, and when the roll is finished the report is ready.
What changes on your line is not the path of the fabric but the path of quality information: the fabric runs through the same machine in the same way, but now each detected defect is on record. That is why Serkon.AI Q2 and Q2 Lite work as a plug-in on your existing inspection machine, without changing operating habits. The page where we explain how the system works, with visuals: How It Works
3. Which defects does it detect?
Serkon.AI Q2 detects 30+ defect types in real time. Woven and knitted defects such as holes, stains, thick picks, needle lines, floats, streaks, slubs and fly contamination are among them. Each defect type is recorded with its own label, so the report does not stop at "12 defects on this roll" — it shows how many of each type there are and where they are.
A defect list on its own is not a sufficient yardstick; what matters is that the defects typical of your fabric are detected. That is why we recommend evaluating the system with your own defect samples (see Question 4).
Accuracy and speed
4. What is the detection accuracy? Can you give a percentage?
The honest answer: accuracy depends on fabric type, defect type, ground color and line conditions, so announcing a single percentage for all fabrics would be misleading. Rather than a figure in a brochure, the only evidence that means anything for you is a test with your own fabric.
We run that test in our R&D lab with your real fabrics: you bring rolls that contain your typical defects, and we look together at what the system detects and what it misses. In any case, the real advantage of AI is not a percentage but consistency: it marks the same defect in the same way regardless of operator or working hours, and it is not affected by fatigue, attention or differences in experience.
The real advantage of AI is not a percentage but consistency: it marks the same defect in the same way regardless of operator or working hours.
5. How fast does it run — will it slow my line down?
In manual inspection, most standards keep the speed below roughly 15 m/min for reliable detection, which is why quality control becomes the speed limit of production in many mills. Serkon.AI Q2 scans the fabric continuously along the roll at 50+ m/min; the compact Q2 Lite is designed for speeds up to 30 m/min.
So the system does not slow the line down — on the contrary, it stops the inspection step from being the speed limit. The right question is not "what is the maximum speed?" but "does detection stay consistent at my line speed?" — and again, the answer comes from a test with your own fabric.
6. Does it work on patterned, printed or dark fabrics?
Plain-dyed grounds — light or dark — are where the system is strongest, and good results are also achieved on difficult grounds such as slub fabrics. Patterned and printed fabrics are the hardest area of visual inspection: this is true of manual inspection too, and standards keep the inspection speed even lower for patterned fabric.
Development in this area is ongoing; for now, our preference is plain-dyed fabric grounds. If patterned products make up a large share of your fabric mix, tell us at the start of the conversation, and we will clarify in the test what results to expect on which qualities.
Installation and fit
7. Do I have to replace my existing inspection machine?
No. Serkon.AI Q2 and Q2 Lite work as a plug-in on your existing inspection machine, without changing operating habits — whether it winds fold-to-roll, roll-to-roll or batch-to-roll. A flat section where the fabric passes is enough for installation. Your existing machine keeps working; a scanning and recording layer sits on top of it.
Q2 Lite is designed specifically to digitise an existing manual inspection machine; Q2 is the main system for high-speed lines and is installed either on a new line or as a plug-in on an existing machine. We decide together in the pre-assessment which one fits your line. We have collected the other questions to ask before buying here: 10 Questions to Ask When Choosing a Fabric Inspection Machine
8. Which fabric types is it used on?
Plain woven grounds, knits (single jersey, two-thread and three-thread fleece, interlock, rib), denim, automotive and technical textiles, and upholstery fabrics are the main groups the system works on. We do not draw a line between knitted and woven; each group has its own defect signature, and the system recognises defects accordingly.
9. How long does installation take, and how long does the line stop?
Installation takes 1–3 working days after delivery, training 5–10 working days; the exact timing is confirmed in the pre-assessment, based on your existing machine and winding type. The installation plan sets out in advance where the unit will sit, where the screen will stand, how the ERP connection will be set up and in which time window the line will stop.
For the first month after installation, the system is also monitored remotely and operators receive support; a 24/7 support line is available for questions. Detection and recording run locally; if the internet drops, the line keeps running. The internet is needed for remote support, licence checks, updates and cloud reporting.
Operators and daily use
10. What happens to our operators?
The operator does not disappear — the role evolves. In manual inspection, the operator's job is to scan the fabric by eye. On an AI-supported line, the operator manages the system, reviews detections, corrects them where needed and approves the final quality decision.
This change means inspection labor is used more effectively. The operator manages the line instead of scanning the fabric by eye — often with up to 50% less inspection labor than manual methods required. The effort that remains goes into decisions and line management. We looked at how to calculate labor cost in quality control here: Reducing Labor Cost in Quality Control — The Impact of AI
11. If our experienced staff leave, will our quality standard drop?
This is the problem mills run into most: quality assurance often depends on the judgement of a few experienced people, and when they leave, the standard can leave with them. A new operator may look at the same roll differently — and the buyer may notice the difference.
Serkon.AI keeps this experience in the system, not in the person. Decisions made on the line and actions taken in reporting are recorded; these records are analysed and turned into the system's classification settings — how each defect is assessed on each fabric. So the knowledge "we ship this quality to this customer under these conditions" lives in a defined rule, not in one person's memory.
The decision criterion no longer changes from person to person. When the operator changes, the line keeps running to the same standards. Your quality standard becomes independent of staff turnover.
12. Is it hard to learn?
No. The interface is designed for the operator at the line: the fabric style is selected at the start of the lot, scanning starts, defects appear on screen as a live defect map, and the operator reviews detections and approves the roll. When Q2 defect detection + Colortron color control are installed on the same line, both are monitored from a single control screen.
13. What happens if the system meets a defect type it has not seen before?
Serkon.AI Q2 is a system that grows with your production: defect types specific to your mill can be defined in the system under your own names and are then detected automatically. Q2 Lite comes ready to use and runs out of the box.
After installation, the detections that build up are reviewed together with your team, and defect names and the record format are adapted to your quality language. Short answers on how this works are on our Frequently Asked Questions page.
Data, reporting and cost
14. How are defects recorded and reported?
Each defect is recorded with its roll, position and type, and a live defect map builds up across the fabric width. When the roll is finished, the report is ready: defect list, width map and distribution. The data is available as a report and XML file, and is exported / integrated to your ERP; a barcode carrying the inspection content is also generated.
The physical trace matters as much as the digital record: with the NON-STOP LABEL principle, defects are physically marked at the fabric edge without stopping the line, so the defect position is not lost even if the fabric length changes. The cutting and garment side does not have to search for the defect — it finds it directly. And when a buyer claim comes in, what settles the discussion is not memory but the roll's report.
15. Does it also control color?
Defect detection and color control are separate jobs, and on a Serkon.AI line they are done by separate units: Q2 detects defects, Colortron measures color. Colortron monitors color continuously along the roll under standard D65 light, with repeatable precision up to ΔE 0.05, including shade variation across the width (left, center, right); if the threshold is exceeded, it raises an alert. There is no need to cut a sample and take it to the light cabinet.
The two units can be installed on the same line and managed from a single control screen; Colortron can also be installed later as a plug-in on your existing inspection machine or at the stenter exit. If color is critical for you, ask about it in the first meeting. More detail: Fabric Quality Is One Whole — Defect and Color Control Together
16. What does it cost, and how long does it take to pay back?
The price depends on the model (Q2 or Q2 Lite), your existing machine and add-on units such as color control, so a quote is given after the pre-assessment. The real calculation, however, is not in a price list but in three items: inspection labor (see Question 10), the cost of defects that slip through (rework, claimed rolls, returns) and speed (a line that is no longer held back by inspection).
Once you put these three items in your own numbers, the payback period becomes clear. In the pre-assessment we do this calculation with you, using your own line data.
The best answer is your own fabric
The common thread across all sixteen questions: AI fabric inspection is a layer that turns detected defects into evidence, working as a plug-in on your existing inspection machine, without changing operating habits. Its accuracy shows on your own fabric roll; its payback shows in your own numbers.
Let's test it with your own fabric, and assess together whether Q2 or Q2 Lite fits your line.
Frequently Asked Questions
What is the difference between Q2 and Q2 Lite?
Q2 is the main system, running at 50+ m/min on woven, knitted, denim, automotive and technical textile lines. Q2 Lite is a compact solution that digitises an existing manual inspection machine, designed for speeds up to 30 m/min.
Which winding types does it work with?
Fold-to-roll, roll-to-roll and batch-to-roll. Whatever the winding type, it works as a plug-in on your existing inspection machine, without changing operating habits.
Does it also measure fabric width and length, and calculate 4-Point scores?
Yes. Width and length are verified automatically; defects are recorded with roll, position and type, the 4-Point score is calculated automatically, and the roll grade is set against the threshold you define for each buyer.
How does a demo work?
You bring your own fabric, including rolls with your typical defects; the test is run in our R&D lab on your real fabric. After that, an installation plan and quotation tailored to your line are prepared.
Does the system stop the line?
Not for defect detection: with NON-STOP LABEL, defects are marked at the edge and recorded without stopping the line. For color, Colortron raises an alert when the defined ΔE threshold is exceeded; the decision to intervene rests with the operator and your quality procedure.
