Case Study: Serialization and Aggregation with Helper Code

This case study discusses the implementation of SEA Vision’s Tracker solution with helper code functionality for a pharmaceutical manufacturer’s sterile water packaging line. Integrated with Marchesini’s RE302 bottle labeller and MCV850 case packer, the solution ensured precise serialization and aggregation of both 1000ml and 250ml glass bottles, enhancing traceability, compliance, and efficiency.

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Challenge

The manufacturer needed a robust method to serialize and aggregate round glass bottles where label orientation during packaging made direct code reading unreliable. A unique UV helper code printed on bottle caps needed to be married with the serialized Data Matrix code on each label for accurate tracking. Manual interventions increased error risks, slowed operations, and complicated line clearance and compliance.

Solution

SEA Vision implemented its Tracker solution with the following features:

1. Helper Code Printing and Verification:

A UV printer applied a helper code (invisible under normal light) to each bottle cap. Two dedicated UV cameras on the Bottle Labeller checked the presence and readability of this code before labelling began.

2. Bottle Label Serialization:

A serialized Data Matrix code, batch number, and expiry date were inkjet printed on bottle labels. Two cameras verified these codes before label application, rejecting incorrect labels to ensure data integrity.

3. Post-Label Marriage of Codes:

After labelling, another camera checked the printed Data Matrix code and married it with the helper code on the bottle cap. This marriage enabled downstream aggregation despite the bottle’s random label orientation.

4. Aggregation with Case Packer:

Three UV cameras on the Case Packer read rows of helper codes, ensuring accurate aggregation regardless of label alignment.

A dedicated camera verified booklet presence inside each case, and a thermal transfer printer applied and verified serialized codes on case labels before sealing.

Printing, applying and verifying the serialization label on the case.

System Management

The Tracker system was managed remotely via SEA Vision’s L3 solution, providing centralized batch management, serialization management, serial number provisioning, and user access control through Active Directory.

Results

The solution delivered significant operational benefits:

• Enhanced Traceability: The marriage of helper codes with serialized labels ensured full product traceability and regulatory compliance.

• Increased Efficiency: Automation eliminated manual scanning, streamlining the packaging process.

• Error Reduction: Multiple verification stages reduced the risk of serialization or aggregation errors, improving overall product quality.

• Flexibility: The system handled multiple bottle sizes (1000ml and 250ml) within the same line, supporting diverse production needs

Other Applications

This Tracker solution with helper code integration is adaptable for various pharmaceutical packaging lines requiring precise serialization and aggregation of products with challenging geometries or labelling constraints.

Learn More

For further information about SEA Vision's Track & Trace solution and Marchesini Group’s MCV820 case packer, visit:

• SEA Vision Track & Trace Solution