Overview
A global life sciences manufacturer struggled with manual vial counting, a slow, labor-intensive process that hindered productivity, accuracy, and compliance. With batch reconciliation delays across four production lines and a 15% annual market growth, scaling production was essential—but facility expansion was not an option.
To overcome these challenges, Catalyx deployed the Catalyx Vial & Syringe Counter, a mobile, intelligent counting system powered by advanced vision algorithms. This solution automated vial counting, improving speed, accuracy, and scalability while integrating seamlessly into existing workflows.
Challenges
Manual Counting Slowing Productivity & Compromising Accuracy
The production team faced inefficiencies due to manual vial counting, a slow and error-prone process that hindered productivity. This labor-intensive method affected four production lines, causing batch reconciliation delays, increased operational strain, and inconsistent counts that risked compliance and product integrity. To enhance accuracy, efficiency, and scalability, an automated solution was essential.
Meet Market Demand Without Expanding Infrastructure
The company needed to scale production to meet market demand, which was increasing by 15% annually, while operating within existing infrastructure constraints. With facility expansion not an option, optimizing efficiency, resource utilization, and process automation became essential to sustaining growth and competitiveness.
Our Solution
The Catalyx Vial & Syringe Counter
A Game-Changer in Automation
By following this structured deployment process, Catalyx successfully automated the vial counting process, eliminating manual inefficiencies, enhancing accuracy, and improving overall production efficiency.
Step 1: Implemented a Mobile, Intelligent Counting Solution
Catalyx introduced a standalone, intelligent, and mobile counting system powered by advanced vision algorithms. This automated vial counting across the facility, with its mobile design enabling it to serve all four production lines.
Step 2: Trained the System for Accuracy
Collected various vial samples from the customer and trained the system by setting up vision files and recipe configurations to ensure precise counting.
Step 3: Integrated the Printing System for Reconciliation
Integrated a printing system to generate reconciliation reports for each tray.
Step 4: Conducted Factory Acceptance Testing (FAT)
- Pre-tested the solution in a controlled environment before on-site deployment.
- Verified system accuracy, ensuring it met customer requirements before installation.
Step 5: On-Site Installation & Validation
- Installed the system at the facility within 3 days and conducted Site Acceptance Testing (SAT).
- Fully integrated the solution into production workflows, ensuring seamless operation and accuracy.
Outcomes:
50% Faster Vial Reconciliation
Reduced vial counting and reconciliation time across all four production lines, improving overall efficiency.
Error-Free Counting
Automated precision ensures audit-ready batch records with zero counting errors.
Seamless Integration & Mobility
Effortlessly transitions between production lines with full-spectrum vial color recognition, enhancing operational flexibility.
Scalability Without Expansion
Adapts to various tray and vial sizes with rapid changeover capabilities, supporting increasing demand without infrastructure expansion.
1,500+ Hours Recovered Annually
Efficiency gains equivalent to producing 70 additional batches (average batch size: 800L).
Supports 200+ annual batches: Eliminated Need for Additional Fill Lines.
Workforce Optimization
Freed two-thirds of personnel from manual counting, allowing them to focus on higher-value tasks.
Conclusion:
By implementing the Catalyx Vial & Syringe Counter, this life sciences leader not only achieved immediate efficiency gains but also future-proofed its operations for long-term scalability and continuous growth. With error-free counting, 50% faster vial reconciliation, and 1,500+ hours recovered annually, the company eliminated the need for additional fill lines while redeploying its workforce to higher-value tasks. The successful integration of automation into vial counting has transformed operational efficiency, allowing the company to meet growing market demands without infrastructure expansion.