Inspection Technology

WELCOME TO THE WORLD OF INSPECTION TECHNOLOGY

Inspection is a key quality safeguard for pharmaceuticals, and contributes significantly to patient safety. It also helps to improve the entire production process.

Pharmaceutical manufacturers must pay attention to sterile filling and material integrity to ensure the highest product safety. The containers run through many different stages, i.e. washing, siliconizing, sterilizing, filling and closing. They are exposed to different temperatures, pressures, and high-speed movements. This is where inspection technology comes into play.

Know how

APPLICATION KNOW-HOW FOR AN EXTENSIVE PRODUCT RANGE

Syringe

Syringe
Vial liquid

Vial liquid
Cartridge

Cartridge
Vial lyo

Vial lyo
Ampoule

Ampoule

One single technology is not sufficient to inspect all drugs at the highest standards. Key is to find the most suitable technology for your container type and product.

Visual inspection expertise
Innovative and highly accurate inspection: Camera-based inspection

Our high-resolution camera systems are robust devices for detection of cosmetic defects and particles in low- to high-viscosity products.
Reliable and easy to validate: Static division (SD) technology

A light transmission-based method for moving particle inspection in liquid products.
Difficult to inspect products
Challenging product characteristics

Some products limit the ability to detect particles. They require advanced know-how and technology.
Milky product / Heavy suspension

Challenge: Particles inside a milky liquid are only visible when they are close to the surface of the inner container wall.

Low-filled containers (Fill levels under 3-5 mm)

Challenge: Many particles are invisible as they are covered inside the meniscus. It is difficult to keep them in motion and move them to the limited visible area.

Lyophilized products

Challenge: White particles, glass particles and white fibers are hard to distinguish from the lyo-cake background. The application of inspection cameras at many different positions around the container is required.
Artificial Intelligence applied to visual inspection
How can Artificial Neural Network algorithms optimize your inspection results?

EFFECTIVE
- Detection rates up to 100 %
- False reject rates down to 0 %
VALIDATED
- System ready for qualification
- Already in use in manufacturing line
SIMPLE
- Seamless integration into vision system
- Only 3 vision tools per recipe
ECONOMICAL
- Potentially millions of dollar in annual savings
- Less machine idle time for recipe tuning
Artificial Intelligence applied to visual inspection
Container closure integrity testing
Container leaks might lead to a change in the active pharmaceutical ingredient: drugs can lose their efficacy or lead to unexpected side effects.

Container defects:
Laser-based headspace analysis

Measurement of absorption by oxygen and/or moisture molecules to detect permanent and temporary leaks.
- Very gentle, non-destructive measuring method
- Preferred technology for products filled under vacuum or inert gas
High voltage leak detection

This container closure integrity testing is based on electrical conductivity measurements. High voltage is applied across the containers filled with conductive liquids. An elevated electrical current indicates a leak.
- Reliable leak testing even for filling products with low conductance and minimal contents
- Holistic measuring system to cover the whole container surface
Combined machine platforms
Profit from our modular machine concept
AIM296 Plus

Utilizing Static division and camera-based technolgy for visual inspection and high voltage leak detection module for CCI testing

AIM3000 Series

Combining camera-based inspection technology and high voltage leak detection module
Product portfolio
AIM 8000 Series: Automated Inspection Machine for Vials and Ampoules

Designed to handle the wide range of containers at the maximum speed of 600 containers per minute. It can inspect liquids (including highly viscous products and suspensions) and lyo products, either in vials, ampoules or syringes.

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AIM 8000 Series: Automated Inspection Machine for Syringes

Designed to handle the complex assembly of syringes through proven technologies. Inspect at the max. speed of 600 containers per minute. As an option, AI technology can be added to distinguish particles from bubbles precisely.

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AIM 3000 Series: Automated Inspection Machine with CCI testing

Automated Inspection Machine for ampoules and vials for particulates, cosmetic defects and leak detection at up to 24,000 containers per hour – on one single machine platform.

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AIM 3000 Series: Automated inspection machine with modular design for highest flexibility

Thanks to its modular design, AIM3000 can be adapted optimally and inspect ampoules or vials, liquids or lyophilized products. For CCI testing, high voltage leak detection and headspace analysis are available.

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AIM 2000 Series: Automated Inspection Machine for Cartridges and Vials

Proven and reliable technology based on long-term experiences with dental and insulin cartridges. At the maximum speed of 400 c.p.m, vials can be also inspected on one platform.

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KHS: Laser-based headspace analysis machine for automatic leak detection

Syntegon and Lighthouse Instruments join their complementary strengths to offer best-in-class headspace leak detection machines!

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Fully integrated syringe inspection line without glass-to-glass contact

Pursuing a fully integrated approach, the line offers a holistic solution for the de-nesting, inspection and re-nesting of pre-filled syringes.

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