Pharmaceutical and Medical Packaging News
Magazine
PMPN Article Index
Originally Published PMPN July 2005
Product Update
Catching the Details with Inspection Systems
In-line and off-line systems are charged with a host of duties, ranging from code verification to contamination detection.
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Color Camera
An intelligent camera is capable of acquiring and analyzing color images in real time for inspecting manufactured parts. The T23 is the latest addition to the IMPACT T-series intelligent camera line.
According to the manufacturer, this series is the industry’s first line of intelligent cameras that include all of the features of a full-scale vision system built right into each camera, delivering a cost-effective alternative to high-end vision inspection systems. The T23 is designed to perform complex color inspections by rejecting products that fall outside of a preset color range. The camera can be used for color-based sorting, color-code verification, and paint-defect detection. A single-software platform called Inspection Builder supports the entire IMPACT line of products. Inspection Builder now contains powerful color-image processing algorithms in combination with a broad range of grayscale algorithms, which permits the T23 to be used for color- and grayscale-image analysis simultaneously. PPT Vision, Eden Prairie, MN; 952/996-9500; www.pptvision.com.
Optical Character Verification System
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An optical character verification (OCV) system helps ensure that information is correctly printed onto pharmaceutical labels and packages. Using the ProofRead system, manufacturers can make sure that the correct date, lot, or product code is printed; the correct labels are placed onto products; and the correct product is placed into a carton or box. The system features OCVMax, a character-verification technology. With this feature, characters can be verified even when they are printed onto a curved or flexible surface or when they are distorted during printing or packaging. Because it can tolerate print distortion, the ProofRead system helps minimize false rejects and eliminate costly operator intervention. A graphical user interface guides users in configuring vision tasks, cameras, and I/O. A touch screen interface enables line operators to easily view images, review results and statistics, and perform product changeover. Built-in security, change tracking, and logging capability are included. Cognex Corp., Natick, MA; 877/264-6391; www.cognex.com.
Leak-Testing System
A system for detecting leaks and testing seal integrity is available in a variety of configurations, including pressure decay, differential pressure, and mass flow. The SigLEAK test system uses proprietary signature-analysis software to capture and analyze complete leak-test waveforms in real time. Using all the data points on the waveform leads to increased accuracy and better gauge repeatability and reproducibility than traditional leak-test systems that rely solely on initial and final pressure levels. The SigLEAK system is designed to minimize false rejects and improve manufacturer efficiency and yield. It helps users visualize and identify the key elements of the leak test for a specific product. Instead of collection and analysis of the complete waveform, individual zone testing can be performed on specific key features, which results in reduced cycle time. The system takes the values from key features and compares these against acceptable limits to determine pass or fail status. Sciemetric Instruments, Ottawa, ON, Canada; 613/254-7054; www.sciemetric.com.
Decoder Software
Software for reading codes is available with an expanded feature set and operational range. The decoder deciphers rectangular and square ECC 200 datamatrix codes with module sizes from 6 ¥ 6 to 144 ¥ 144 cells. An advanced auto-detection mode automatically determines the size, number of modules, and bright-on-dark or dark-on-bright code types and adjusts the reader engine accordingly. The decoder software is able to read the codes reliably as fast as 40 codes per second when running on a DSP processor. Codes can be read when they are damaged, distorted, displaying low contrast, or laser engraved. The company offers a one-time license charge with no run-time fee. Vision Components GmbH, Hudson, NH; 603/598-2588; www.vision-comp.com.
Print-Quality Inspection
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A standalone print-quality inspection appliance is sized at a compact 50 ¥ 50 ¥ 170 mm, including lens. The smart camera–based instrument can be used to perform narrow web print inspection tasks or to check the position, accuracy, and quality of text and graphics that have been machine printed on discrete parts. The PQEye inspection appliance is PC-free; its setup, training, and test procedures are all accomplished using its multifunction keypad and a graphical user interface that displays on standard SVGA monitors. It can inspect the results of offset, flexographic, thermal-transfer, laser, ink-jet, and other printing processes and is capable of addressing applications that were previously the domain of PC-based vision systems. The Value Engineering Alliance, Cambridge, MA; 617/492-1252; www.the-V-E-A.com.
Label Inspection and Gauging
An integrated image-processing system performs a variety of machine vision applications. These include packaging and label inspection, bar code reading, gauging, feature presence/ absence, and pattern matching. The Teli-brand iIS-010 Smart Camera is a prepackaged solution that includes a high-performance CCD camera, a control unit, and software. It simplifies the deployment of machine-vision capabilities without compromising measurement accuracy. Camera electronics support a 60-Hz progressive scan frame rate and are housed entirely within the compact assembly. A single cable connects a remote-head double-speed VGA sensor. A computer interface accessible through Microsoft Explorer guides users during setup and operation, and a simple calibration procedure factors out both perspective and nonlinear lens distortion. Toshiba Teli America Inc., Irvine, CA; 949/ 770-8354; www.toshiba-teli.co.jp.
Noninvasive Leak Checking
A family of products is capable of performing noninvasive checks for leaks in packaging. The Leak Master leak tester features 14 available chambers measuring up to 225 x 775 x 665 mm, depending on the product version. The chambers can accommodate all standard packaging sizes. Only one device is needed for an entire product range, which can include flexible and rigid plastic packaging or crates and PET bottles. A range of models is available, from tabletop units for random sampling to mobile compact models for complete packaging. The Leak Master tester analyzes CO2 as trace gas. This approach is reportedly more cost-effective than testing with helium. The tester is capable of detecting even minor leaks with its ceramic sensor, which detects CO2 at concentrations of between 0 and 5000 ppm. The equipment has a resolution of 1 ppm, and it is immediately ready for use, with no need for calibration. Witt-Gasetechnik GmbH & Co. KG, Witten, Germany; +49 02302 89010; www.wittgas.com.
Chamber Test System
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A nondestructive leak tester produces quantitative leak-test results for blister cards. By combining the sensitivity of pressure- or vacuum-decay leak testing with sealed fixtures, the TME Solution-CBC system can detect holes as small as 5 mm in blister-card backings. This method uses a proprietary chamber design to produce sensitive, consistent, precise test results in a laboratory or quality control environment. The test instrument is a high-resolution pneumatic pressure or vacuum tester. It permits the operator to store up to 100 functional programs and to link programs to design a sequence of tests for specific needs. Touch screen menu-driven operation makes it possible for the operator to control the test parameters, examine statistical analysis of results, and download data files easily. The complete leak-test cycle for blister cards can be performed in less than 30 seconds. TM Electronics Inc., Boylston, MA; 508/869-6400; www.tmelectronics.com.
Vision Systems
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Four systems perform product inspection. The LVS 7000 verifies linear bar codes and 2-D symbols to ISO standards. The analysis can be done on-line for such items as blister packs (verifying multiple codes at one time) and other products in high-speed on-line production processes. The Integra 9500 system performs off-line ISO verification of all major linear and 2-D code symbologies. It is a complete, self-contained, camera-based system capable of auto-discriminating among all linear and 2-D code symbologies. The Integra 9500 AXR has the ability to read large codes or bar codes directly marked on an object. It is attached to the Integra 9500 system by a USB connection, and the results are displayed on the LCD of that system. The LVS 9800 is an automated system for counting inserts and outserts. It counts individual rows as well as container totals for accuracy and accountability and can check both bar codes and color coding. Label Vision Systems Inc., Peachtree City, GA; 800/432-9430; www.lvs-inc.com.
Blow-Fill-Seal Container Inspection
A fully automated and flexible inspection system is available for inspecting plastic containers used as primary packaging for aseptically filled pharmaceutical products. A cost-effective, single-pass alternative to manual inspection, the Ampuscan system is designed to inspect ampules, respules, and other blow-fill-seal–type plastic containers at speeds up to 60 cards per minute, at a high detection rate. The faults for which the system inspects include molding deformities (voids, pits, holes), broken tabs and twist tops, separated ampules including split cards, and others. The system can handle a variety of filled containers, from single ampule units to cards consisting of five or more ampules, plus a range of vials in various shapes and colors. Based on a flexible platform, the system is designed for rapid changeover from one type to another at typically less than 1 hour per change. ATS Automation Tooling Systems
Inc., Cambridge, ON, Canada; 519/ 653-6500; www.atsautomation.com.
Documenting Calibrator
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An ultra-low-pressure documenting calibrator is designed specifically for air-handling processes in critical environments. The Micro-Cal Model 89 calibrator performs calibration checks on sensors with accuracies of up to 0.00025-in. WC. It is portable, lightweight, and compact for use in cramped or remote locations. The battery-powered unit provides a
minimum of 8 hours of operation and a pressure-reading accuracy close to 0.0001-in. W.C. Pressure generation is fast, stable, and repeatable. Recorded calibration times are as fast as five minutes per unit. Additional features include a removable process head and a detachable terminal block. Setra Systems Inc., Boxborough, MA; 800/257-3872; www.setra.com.
Vision-Based Particle Inspection
A particle-inspection system reportedly delivers 100% accuracy with no contact or contamination. The CVT Slitec system features a vision-based technology for inspection of particulates in filled containers. It checks containers for particles using several different images and provides an immediate, automatic second inspection of unconfirmed inspections. It is suitable for more-challenging products, such as suspensions. The patented Sliding Image Technology inspection method requires no moving parts for the camera or lighting systems. Instead, the window of the camera is divided into several virtual frames, so that during the passing of the containers a number of images are taken of each container. The containers travel through two identical inspection stations, which must be in agreement before the container passes inspection. A handling system loads containers into a carousel, where they are secured at the top and bottom, then spun at high speed. The centrifugal force pulls particles to the sides of the container, and the spinning containers are stopped just prior to inspection. The contents continue to rotate and allow the vision system to identify particles suspended in the product. Bosch Packaging Technology, Minneapolis, MN; 763/424-4700; www.boschpackaging.com.
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