A pharmaceutical manufacturer in the Middle East implemented our advanced vision inspection system to ensure complete quality assurance for white tablets packaged in aluminum strip formats. Each strip consists of four individual pockets, each containing a single tablet. With increasing demands for product integrity, traceability, and regulatory compliance, the company integrated SEA Vision’s Harle2D solution on their  packaging line.

The result was a robust system offering real-time quality checks, data verification, and full traceability throughout the packaging process

Read the full case study⬇️

Challenge

In the highly regulated pharmaceutical environment, ensuring the accuracy and quality of solid oral dosage forms is critical. This Egyptian pharmaceutical manufacturer produces white tablets that are packaged in strip formats. Given the importance of avoiding any product defects and guaranteeing regulatory compliance, the company needed a solution that could:

• Inspect tablets for physical integrity on the feeding channels before sealing

• Verify printed variable data such as batch number and expiry date

• Ensure the correct strip reel is in use for every packaging run

To achieve these objectives, the company selected SEA Vision’s Harle2D system for its unmatched ability to provide real-time control and high-speed inspection within a seamless workflow.

Solutions

System Components and Controls

1. Tablet Quality Inspection

Two additional cameras, supported by high-intensity LED light bars, inspect every single tablet before it is sealed into its respective strip pocket. The Harle2D system analyzes:

• Color

• Shape

• Dimensions

• Integrity

• Coating quality

Only defect-free tablets proceed to final packaging, reducing the risk of recalls or compliance violations.

2. OCV/OCR Control

The Harle2D system manages the printing and inspection of critical variable data, including the batch number and expiry date, printed on each pocket of the aluminum strip. Two dedicated cameras equipped with LED light bars perform Optical Character Verification (OCV) and Optical Character Recognition (OCR) to ensure 100% accuracy of the printed information. This control guarantees full compliance and traceability for every unit.

3. Alucode Control

A pre-printed code on the side of the aluminum strip reel is validated to ensure the correct artwork and materials are being used. This verification step is essential for material traceability and compliance with labeling regulations. Due to the reflective nature of aluminum, accurate reading can be challenging. SEA Vision overcomes this with specialized lighting and camera placements that eliminate false readings and enable perfect code recognition under difficult conditions.

Integration and Implementation

The Harle2D system was seamlessly integrated with the packaging machine. Key elements of the integration included:

• Strategic Camera Placement: Each control point - OCV/OCR, Alucode, and product inspection - was equipped with purpose-positioned cameras.

• Optimized Lighting Solutions: Specialized LED bars minimized issues caused by material reflectivity, particularly important for aluminum foil.

• System Synchronization: Harle2D was fully integrated into the packaging machine’s HMI, enable real-time monitoring and adjustment during production runs.

Results

The implementation of Harle2D delivered immediate and measurable improvements in the production line’s performance:

• Enhanced Tablet Quality Control: Each tablet is checked before packaging, ensuring only high-quality units are sealed and shipped.

• 100% Accuracy in Variable Data: Every pocket's batch number and expiry date are verified in real time.

• Material Verification: The Alucode system prevents the use of incorrect or mislabeled reels, increasing compliance.

• Operational Efficiency: Integration with existing workflows was smooth, enabling higher productivity without extensive retraining or downtime.

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Conclusion

This case exemplifies how advanced vision systems like Harle2D play a pivotal role in modern pharmaceutical manufacturing. By combining real-time inspection with seamless integration, our client significantly boosted their product quality, traceability, and regulatory compliance - all while improving operational efficiency.  

The solution ensures that every tablet, every strip, and every batch meets the highest standards of pharmaceutical quality and safety.

Learn More

For further information about our combined control system visit:

• Harle2D|3D vision inspection system