Manual inspection relies on sampling, operator judgment, and intermittent visibility. This approach increases the risk of missed defects, scrap, rework, and compliance gaps.
Automated primary packaging inspection delivers objective, validated results on every unit, at full production speed, across every shift and line
100% In Line Inspection
Our machine vision inspection solutions support the full range of pharmaceutical primary packaging formats used in regulated manufacturing environments, including vials and cartridges, syringes and prefilled syringes, bottles and containers, ampules and multi dose formats, blister packs and unit dose packaging, auto injector pens, sachets, pouches, IV bags, as well as labels and printed variable data.
Comprehensive Inspection Capabilities
Product Integrity and Quality Verification
Ensure every unit meets specification with accurate fill level and volume verification, cosmetic defect detection, particulate inspection, and confirmation of proper assembly and component presence.
Labeling and Data Accuracy
Verify label presence, position, and content while inspecting printed variable data, barcodes, and 1D and 2D codes to support traceability and prevent mislabeling.
Closure and Seal Integrity
Inspect caps, stoppers, and closures for correct placement and integrity, and validate seals using IR and thermal imaging to ensure package security and product protection.
Proven Inspection Performance Across Formats
Vial Inspection
Ensure vial quality and compliance by inspecting cap alignment, stopper presence, and crimp seal integrity. Machine vision verifies fill level accuracy, detects particulates and cosmetic defects, and performs full 360 degree label inspection to confirm correct placement and content.
Syringe Inspection
Validate syringe assembly and product integrity by inspecting plunger height, needle and stylet position, and component presence. Automated inspection confirms fill level accuracy, graduation print quality, and detects foreign material and cosmetic defects to support patient safety and compliance.
Bottle & Ampule Inspection
Inspect bottle cap placement, tamper evident ring integrity, fill level, label position, and variable data, while ampule inspection includes fill level verification, print and code inspection, burn mark detection, and defect identification for single and multi dose lines.
Blister Packs, Sachets & IV Bags
Detect missing or damaged tablets, incomplete capsules, pocket defects, artwork and barcode errors, foil alignment issues, and inspect sachets and IV bags for human readable text, printed codes, inserts, oxygen absorbers, seal integrity, and closure quality using advanced vision and thermal imaging.
Engineered for Compliance
Primary packaging inspection systems are engineered specifically for pharmaceutical environments where traceability, validation, and data integrity matter.
Objective and repeatable inspection results
Fully audit trail ready data capture
Support for IQ, OQ, and PQ validation
Integration with MES, QA, and serialization systems
CASE STUDY
AUTOMATED VISION:
Pharma Efficiency Boost: 50% Faster Reconciliation & 70 More Batches Annually
A leading pharmaceutical company needed a faster, more efficient vial reconciliation process. The Catalyx OpenStation Vial and Syringe Counter reduced reconciliation time by 50%, enabling 70 extra batches annually. Workforce optimization allowed two-thirds of manual counters to be reassigned to higher-value tasks, maximizing productivity without expanding fill lines.
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