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Minimizing Error

PharmaManufacturing.com

Human error can occur at any stage in the drug manufacturing process. Machine vision systems will never replace operators but they can empower them to reduce errors and improve efficiency.

One of many areas where machine vision systems are proving their worth is in publishing information and inserts as well as labels for various products and strengths of medication, in different languages and following different regulatory guidelines for markets all over the world. Managing any pharma labeling and information publishing is a bit like running a miniature publishing business.

The potential for error is high. As technology has become more readily available to help pharmaceutical companies with this task, more drug companies are automating portions of the process to ensure quality of product literature and inserts. Companies including Cognex, Optel, Complete Inspection Systems and Global Vision offer automated, machine vision-based systems that can help streamline and decrease the pain threshold for this tedious operation. However, machine vision systems are establishing their worth in many other areas as well.

Below is a sampling of some recent product introductions focused on pharmaceutical industry applications.

Count Tablets and Capsules

The Slat Filler Inspection System offers high-performance vision inspection capabilities provides slat fillers with guaranteed accurate product counts and additional tablet and capsule inspections and verifications. The optical setup and vision analysis algorithms of the Optel Vision Slat Filler Inspector allow for precise tablet and capsule counts in addition to simultaneous verification of tablets’ and capsules’ colors, detection of foreign materials, and detection of defects, which includes broken, chipped, undersized and oversized tablets and capsules. The system also offers verification of product presence in slats after bottle filling. The system can be easily retrofitted onto slats ranging from 16” to 40” with 6 to 20 funnels that have 1 to 30 cavities per funnel. This allows for real-time inspection speeds of up to 420 slats per min.
Optel Vision, Quebec City, Canada, www.optelvision.com

Proof Documents and Publications

Docu-Proof automatically compares files for textual differences and is well suited for the inspection of contracts, publications, artwork, inserts, and manuscripts. The software compares files in like and unlike formats, which allows you to verify inserts or other types of artwork to unformatted text files. Digital-Page compares both graphical and textual elements between files of various image formats. Detailed accountability is attainable with a reporting feature that documents all changes, thereby decreasing the risk of errors. Digital-Page can detect color differences, font changes, location changes and dropped or added text. All systems meet EMEA and FDA 21 CFR Part 11 requirements.
Global Vision Inc., Montreal, Quebec, www.globalvisioninc.com

Look (and act) Smart

The VC Optimum series offers high-performance Smart Cameras with computational power of 8000 MIPS featuring 1 GHz DSP from Texas Instruments. The VC Professional line offers computational power of 3200 MIPS rivalling a 2.6 GHz Pentium and has a 400 MHz from Texas Instruments. Resolutions of up to 2 megapixels and frame rates up to 242 full frames per second. All Vision Components cameras are insensitive to shock and vibration, and have multiple I/O lines for direct control of external equipment. For more complex control tasks, they can easily be interfaced to a PLC. Vision Components GmbH, Ettlingen, Germany, www.vision-components.com

Check Tablet and Capsule Surfaces

Machine Vision Technology’s vision-based tablet inspection systems use OCR and/or Optical Character Verification to inspect tablets for the presence and quality of multiple characters stamped or printed on both surfaces. The systems are suitable for both flat and convex tablets in all shapes — round, oval, oblong, triangular, square, tear-shaped, etc. The surfaces of the faces and sides of the tablet can also be inspected for defects such as chips, cracks and protrusions, as well as for the presence and position of a drug release hole. The capsule inspection system checks capsules for surface defects, such as contamination and bubbles, and rotates individual capsules. This enables the system to implement OCR on logos and/ or dosage values on 360° of the capsule surface.
Machine Vision Technology Ltd., United Kingdom, www.machinevision-technology.co.uk

Full Vision in a Compact System

The In-Sight Micro Vision System packs a complete vision system into a small package that measures 30mm x 30mm x 60mm. With its small size, the In-Sight Micro provides flexible mounting capability with a non-linear calibration tool that enables mounting at angles of up to 45° for various applications. Five new In-Sight Micro models cover a range of price, performance and resolution levels, including a two-megapixel model. In-Sight Micro includes the Cognex vision tool library, EasyBuilder configuration so ware, and VisionView operator interface display.
Cognex Corporation, Natick, Mass. www.cognex.com/micro

Verify Blister-Packed Tablets, Capsules

The TIPS SENTRI vision inspection suite enables product security by performing complete veri cation of blister-packaged products. Its imaging technology and use of color-content analysis ensures absolute inspection of tablets, capsules, soft gelatin capsules and coated pills. Typical applications performed by SENTRI include lot and date code verification; component code verification; label placement and alignment; cap closure and alignment; label print quality verification; data matrix code reading; bar code reading and verification (including RSS); bar code grading (including RSS); color verification; product presence, shape, color and count; product defect detection; parts gauging and dimensional check; counterfeiting and diversion control; product traceability; and color blister pack and blister lid stock verification.
SYSTECH International, Cranbury, N.J. www.systech-tips.com/tips_sentri.php

Compare Documents, Check Bar Codes

The Q-Spec system is used to quickly capture an image of an incoming or finished product, and to place the image in a database of products, organized by date and lot code, bar code value, or any other criterion the user chooses. The system automatically compares all the printed copy and reads bar codes, including 2-D data matrix codes, allowing products to be searched and sorted with a minimum of manual input. The Q-Spec system consists of a computer and an imaging workstation with a 10.3-megapixel camera, and a software suite.
Complete Inspection Systems, Indialantic, Fla. www.completeinspectionsystems.com

User-Friendly Connections

The Fiber-Lite DC950H Machine Vision Fiber Optic Illuminator is a 150-watt quartz halogen regulated illuminator, which has been improved to produce a higher output with additional reliability, and is now RoHS compliant. It features DC regulated output, quick lamp response, and a 0-5 VDC remote intensity control interface with linear voltage adjustment (8 bit D/A module available). Several illuminating options are available, including: color filtering, manual iris (for intensity adjustment at a constant color temperature), and an analog or digital remote interface.
Dolan-Jenner, Boxborough, Mass., www.dolan-jenner.com