Digitalize Your Existing Inspection Machine Without Replacing It: A Retrofit Guide (Q2 · Q2 Lite)
You do not have to replace your inspection machine to strengthen quality control. In many mills the traditional inspection machine has run for years and does its job; what is missing is not the machine but the scanning and recording layer. Retrofit adds exactly that: the machine stays, and a system that detects and records defects goes on top.
This article is written for production and quality managers evaluating a retrofit decision: which machines it fits, how to choose between Q2 and Q2 Lite, how many days installation takes, how long the line stops, and what changes on the line after installation, and what does not. The general questions to ask before a purchase are collected separately in 10 questions to ask when choosing an inspection machine.
What retrofit means: the machine stays, evidence is added
In fabric inspection, retrofit means mounting a camera and lighting unit with recording software on top of the existing inspection machine. Serkon.AI Q2 and Q2 Lite work as a plug-in on your existing inspection machine, without changing operating habits. The fabric passes over the same table, at the same speed, with the same operator; the difference is that the fabric is now being scanned and every detected defect is recorded with its roll, position and type.
On the investment side the meaning is clear: no new line is built, the money already paid for the existing machine is preserved, and installation is measured in days. On the quality side the meaning matters more: in manual inspection a defect may be noticed, but it is not always systematically recorded; after retrofit every defect is in the record.
Which machines it fits: three winding types
For installation, a flat section where the fabric passes is enough; the unit is mounted above this section, parallel to the fabric width. The winding type of your existing machine does not matter:
Winding type | Typical use | Retrofit note |
Fold-to-roll | Fabric arriving folded is inspected and wound onto a roll | The fabric passes taut over the table; the unit sits above the table |
Roll-to-roll | Roll-to-roll inspection; the most common setup in knitting and weaving | Feed and winding stay the same; the unit mounts above the fabric path |
Batch-to-roll | Heavy fabric arriving from a big batch roll is wound onto a roll; denim and heavy wovens | The taut fabric path is preserved; the unit can also be installed on a portal at the line exit |
On the fabric side, the system runs on plain woven grounds, knitted fabric (single jersey, two-thread and three-thread fleece, interlock, rib), denim, automotive and technical textiles, and upholstery fabrics. Plain dyed grounds are preferred; development continues on patterned and printed fabrics. In the pre-assessment we answer not only "which fabric" but also "on which machine, with which winding type".
Q2 or Q2 Lite?
Both products are installed on the existing machine; the difference is line speed and line structure.
Model | Speed | Typical installation | Who it is for |
Serkon.AI Q2 | 50+ m/min | New line, or mounted on an existing inspection machine | High-speed lines; woven, knitted, denim, automotive and technical textiles |
Serkon.AI Q2 Lite | Up to 30 m/min | Digitalizes the existing manual inspection machine | Mills that want to digitalize while keeping their existing machine |
Q2 Lite is designed specifically to digitalize the existing manual inspection machine; Q2 is the main system for high-speed lines and is installed on a new line or mounted on an existing machine. Both detect 30+ defect types in real time and work with the same recording logic. Which one fits your line is decided in the pre-assessment, with your own fabric and your own speed.
Installation step by step
Pre-assessment: You bring your fabric to our R&D laboratory, or a live pre-assessment is planned with fabric samples from your line. Winding type, line speed and fabric types are clarified here, and Q2 or Q2 Lite is recommended for your machine.
Installation plan: Where the unit will be mounted, where the screen will stand, how the ERP connection will be set up and in which window the line will stop are all decided in advance.
Installation: Installation takes 1–3 working days after delivery; the exact duration depends on your machine and winding type and is confirmed in the pre-assessment.
Training: Operator training takes 5–10 working days. Operators learn the interface on the floor; the fabric style is defined at the start of a batch and recalled from the record for later batches.
First month: For the first month after installation the system is also followed remotely and operators are supported; 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.
What changes after retrofit
Every defect is in the record: Every detected defect is recorded with its roll, position and type and marked on the live defect map. The defect is not in someone's memory; it is in the record.
Every roll leaves with its report: The defect list, the fabric width map and the defect distribution travel with the roll; after inspection the system generates a barcode that identifies the inspection content.
The report goes to your ERP: The roll report is exported / integrated to your ERP, so planning, shipping and customer reporting read quality data from the same source. For the details, see the 7 stages of the quality control process.
Consistency: The system marks defects the same way, regardless of operator or working hours.
The operator's role: 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 operator does not disappear — the role evolves: they review detections and approve the final quality decision. The labor side is covered in labor cost in quality control.
What does not change
Your inspection machine, fabric path and winding type stay the same.
Operating habits do not change: the fabric passes over the same table, the same team works.
The final quality decision stays with the operator; the system ties the decision to a record.
Pre-retrofit checklist
Clarifying these six points before the pre-assessment meeting shortens the process:
Your machine's winding type (fold-to-roll, roll-to-roll, batch-to-roll) and the dimensions of the flat section where the fabric passes
Line speed (m/min) — this decides between Q2 and Q2 Lite
The fabric types and ground types you inspect (plain dyed, patterned, printed)
Where the screen will stand on the line, and the number of operators
Report recipients: your ERP system, and which fields planning and shipping need
The report format your buyers ask for (defect list, width map, barcode)
Connect your quality decisions to the system, not to the person.
Let's plan a pre-assessment for your line
Share your machine's winding type, your line speed and the fabric types you inspect, and we will plan a live pre-assessment with your own fabric. At the end you will see the model that fits your line, the installation plan and a sample roll report, together.
Short FAQ
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; fold-to-roll, roll-to-roll or batch-to-roll winding makes no difference.
How long does installation take, and how long does the line stop?
Installation takes 1–3 working days after delivery, and operator training 5–10 working days. The window in which the line stops is decided in advance in the installation plan.
Should I choose Q2 or Q2 Lite?
Line speed decides: Q2 is the main system for lines running at 50+ m/min; Q2 Lite digitalizes the existing manual inspection machine at speeds up to 30 m/min. The decision is made together in the pre-assessment.
Which fabrics does it work on?
Plain woven grounds, knitted fabric (single jersey, interlock, rib), denim, automotive and technical textiles, and upholstery fabrics. Plain dyed grounds are preferred; development continues on patterned and printed fabrics.
If the internet drops, does inspection stop?
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.
For more questions, see the 16 most common questions about AI fabric inspection.
