Vision systems advance quality control capabilities
PROCESS TECHNOLOGIES QUALITY CONTROL
OPTIMAL INDUSTRIAL AUTOMATION
Vision systems advance quality control capabilities
In the pharmaceutical and nutraceutical industries , every pack of oral solid dosage ( OSD ) form and its content must be carefully inspected to guarantee that it meets quality standards and complies with regulatory requirements . While traditional control methods have considerable limitations , by adopting advanced vision inspection methods , manufacturers can transform blister pack inspections into an extremely accurate , precise and efficient operation .
Matt Jones , Account Manager at Optimal Industrial Automation , looks at how state-of-the-art vision systems can advance quality control activities on blister packs .
In the world of pharmaceuticals and nutraceuticals , packaging is paramount . Among the variety of packaging solutions available , blister packs have emerged as a popular choice due to their versatility , costeffectiveness , and tamper-evident features . The individual pockets on the packs protect each OSD form , ensuring precise dosing , tamper evidence and prolonged shelf life . However , their effectiveness depends heavily on the accuracy of the packaging process , therefore , their inspection is a crucial task .
This quality control activity should detect defects in OSD forms , such as chipped or broken tablets as well as any foreign objects on them , and ensure that the right medicaments are being packed . In particular , for lines that process multiple medicines , there should not be any mix-up . It is also vital to spot any empty pocket or OSDs that have been incorrectly positioned within the blister packaging . Following this analysis , any off-spec blister pack needs to be discarded .
Traditional quality control methods , such as manual inspections or basic machinery , often fall short in guaranteeing the required level of precision and reliability . Furthermore , they can contribute to extended , ineffective cycle times . Industrial automation solutions that leverage high-power vision systems can play a key role in effective and responsive inspection of blister packs .
The power of vision system-based inspections Vision systems typically combine cameras , sensors , lighting and advanced software to capture and analyse images of blister packs as they move through production lines . More precisely , the process begins with high-resolution cameras and lights strategically positioned to generate and capture detailed images . The number and their placement depend on the complexity of the inspection required and the specific setup . For example , various lighting techniques can be used . These include diffuse , direct and backlighting , to eliminate shadows , reflections or other image distortions .
Once the images are captured , they are processed by powerful algorithms . These are designed to detect and analyse specific features , irregularities , defects and other attributes of the blister packs - and the tablets within - that could compromise product quality or safety . The software compares the images against predefined criteria to determine whether each pack meets the required quality standards .
Blister packs that pass the inspection are allowed to move to any downstream operation , while those that have been flagged are automatically diverted and rejected from the line . This ensures that only compliant packs make their way to the next stages .
Vision systems can also provide detailed data and documentation of the inspection process , including images of inspected blister packs , timestamps and records of any defects detected . This information can support comprehensive reporting and quality auditing activities to ensure regulatory compliance . Even more , they support traceability strategies .
The future ahead
With the capabilities of artificial intelligence ( AI ) evolving considerably , vision systems are deemed to become even more complex , accurate and smarter . For example , they can integrate increasingly advanced spectral functions , sensors , pattern recognition algorithms and data processing functions . Thanks to these , they can detect subtle anomalies that may not otherwise be identifiable .
For further information , please visit www . optimal-ltd . co . uk
98 PECM Issue 67