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MEDICAL & PHARMACEUTICAL SUPPLEMENT


INSPECTION FOR DETECTION


Adding vision systems to pharmaceutical packaging production lines can help manufacturers maintain advanced quality


control, as Matt Jones, account manager at Optimal Industrial Automation, explains


ackaging is paramount in the world of pharmaceuticals and nutraceuticals. One of the most popular choices is the blister pack, with the individual pockets on the packs protecting each oral solid dosage (OSD form), ensuring precise dosing, tamper evidence and prolonged shelf life. But with their effectiveness depending on the accuracy of the packaging process, inspection is critical. Inspection should detect defects in OSD


P


forms, such as chipped or broken tablets as well as any foreign objects, and ensure that the right medicaments are being packed. For lines that process multiple medicines, there should not be any mix-up; and it is also vital to spot any empty pocket or OSDs that have been incorrectly positioned. Off-spec blister packs then need to be discarded. This is where vision systems come into play. Installing vision systems – which are


typically a combination of cameras, sensors, lighting and advanced software – can capture and analyse images of the packs as they move through production lines.


CAPTURING DATA 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. Various lighting techniques can be used, including diffuse, direct and backlighting, to eliminate shadows, reflections or other image distortions. Once captured, the images 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. 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


Vision systems can capture and analyse images of the packs as they move through production line


consisting of two vision systems monitoring the products as they move on a conveyor. The first component identifies a faulty item and tracks it, while the second, located at the end of the line, rejects any unsuitable pack. The three identical solutions look for colour, shape and dimensions, as well as absence of OSD forms. To support the advanced functions of the


new machines as well as the needs of the remaining equipment, Optimal replaced the controller with a more powerful PLC which can handle data-intense operations while offering a scalable framework.


Optimal Industrial Automation (OIA) https://optimal-ltd.co.uk


MARCH 2024 DESIGN SOLUTIONS - SUPPLEMENT 35


auditing activities to ensure regulatory compliance. Even more, they support traceability strategies. With the capabilities of artificial intelligence (AI) evolving, vision systems will become even more complex, accurate and smarter in the future. For example, they can integrate increasingly advanced spectral functions, sensors, pattern recognition algorithms and data processing functions. This means they can detect even subtle anomalies. Plus, thanks to the latest


progress in unsupervised machine learning and deep learning, creating accurate vision systems is becoming quicker. The development of innovative 3D vision


technology will allow vision systems to provide even more detailed and accurate quality control, particularly for complex blister pack designs.


MACHINE DEVELOPMENT In one example, a tablet manufacturer experienced a sudden breakdown of its three blister pack inspection machines, so got in touch with Optimal Industrial Automation. To help, the company developed new inspection machines


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