INDUSTRY
Pharmaceutical & Medical Device Industry
In pharmaceutical and medical device production every product must be traceable, every label correct and every package complete. Automation systems have to read small barcodes and alphanumeric codes at high speed and make sure that only defect-free product leaves the line. Machine vision and code reading bring serialisation, label verification, packaging inspection and assembly checks together in a single traceability chain. Below are the application areas we meet most often in this industry and the product groups we use for each.
Serialisation and traceability (track & trace)
Challenge
Regulations require the serialised DataMatrix code on every saleable unit to be read and recorded. The code is small, the line is fast and the pack surface may be glossy or curved; a single missed read can stop the batch.
Solution
Fixed-mount code readers read the 1D/2D codes on cartons, bottles and blisters at line speed and pass the result to the MES/ERP. Read rates on curved or low-contrast surfaces are raised with the right lens and lighting.
Expiry date and lot code verification (OCR/OCV)
Challenge
Printed date and lot information can be faint, shifted or simply wrong. A wrongly coded product that reaches the market means a recall.
Solution
Vision sensors read the printed text on every unit (OCR) and compare it with the expected value (OCV); faint or missing print is rejected immediately.
Label inspection and verification
Challenge
A wrong label, a missing label or illegible print is the most common cause of mix-ups in pharma. Presence, correct product, position and legibility all have to be checked at once.
Solution
A smart camera captures the label and its code in one frame; presence/absence, pattern match, code reading and position check are done in the same cycle, and a reject signal goes to the labeller.
Cap, safety ring and tamper-evident seal inspection
Challenge
A missing or damaged safety seal puts product integrity in doubt; cap height and ring breakage cannot be judged by eye at line speed.
Solution
The camera measures cap position, ring integrity and seal presence; a 3D sensor checks cap height and tilt.
Blister and packaging integrity inspection
Challenge
Empty cavities, broken tablets, wrong colours or foil misalignment must be caught before cartoning. There are many product variants and changeover time is short.
Solution
An area scan camera with suitable lighting images every blister; cavity fill, colour and shape are checked, and on changeover the matching recipe is loaded from the library.
Tablet and capsule quality inspection
Challenge
Print defects, deformation, cracks and surface flaws are hard to separate from acceptable variation and difficult to describe with rule-based algorithms.
Solution
A high-resolution camera and deep-learning based vision software learn defect classes from examples; the system makes the accept/reject decision at line speed.
Vial, ampoule and syringe inspection and counting
Challenge
Micron-scale cracks, particles and fill-level deviation in glass containers must be detected, and every piece has to be accounted for throughout the process.
Solution
Several cameras image the container from different angles; fill level, cap and body defects are inspected. Camera-based counting shows where count deviations originate.
UDI marking and verification on medical devices
Challenge
The unique device identifier (UDI) is marked directly on metal or plastic (DPM). The small, low-contrast code on a reflective surface has to be both read and quality-graded.
Solution
A DPM-capable code reader with angled or dome lighting reads the code on every part; parts with falling read quality are fed back to the marking process.
Medical device assembly verification and measurement
Challenge
Small components, tight tolerances and high volumes: a missing part, a mis-seated part or a dimensional deviation has to be caught before it reaches the field.
Solution
Edge-finding and measurement tools check part position and dimensions; for assemblies with variable appearance, example-based classification is used. A 3D sensor measures height and flatness.
Presence, position and safety on the line
Challenge
As much as the vision system, the sensors that detect the product at the right moment and place and the safety equipment that protects the operator are part of the line.
Solution
Photoelectric sensors handle triggering and presence detection, pressure sensors monitor filling and pneumatics, and safety light curtains and door switches provide machine guarding.
Let’s define the application on your line together
We select the right camera, code reader and lighting for your product, packaging and line speed, and run a pre-test on samples where needed. Contact us →