Case study: SV 26 | Vision Inspection for Syringe Packaging Line

This case study highlights the successful implementation of SEA Vision’s OCV Multipurpose and HarleTray inspection systems for a leading pharmaceutical manufacturer in the USA.

The project delivered a fully automated syringe packaging solution, improved product quality assurance, operational efficiency, and compliance with regulatory standards.

Read the full case study⬇️

Challenges

The pharmaceutical company faced several operational and compliance challenges:

• Quality Control: Verifying the correct presence, assembly, and orientation of all components in varying tray formats.

• Regulatory Compliance: Ensuring accurate label placement and data to meet international standards.

• Operational Flexibility: Supporting multiple packaging formats with rapid changeover and minimal downtime.

• Data Visibility: Providing transparent inspection results to operators and quality teams.

Solution

To address these challenges, SEA Vision deployed a multi-stage vision inspection solution across four key machines in the packaging line:

1. Syringe Denester

• Nest Completeness and Syringe Count
  A camera inspects each nest to confirm all syringes are present before further processing. Incomplete nests are automatically rejected, ensuring only valid products continue down the line.

2. Syringe Detrayer

• Tray Orientation Check
  The vision system verifies the orientation of each tray. If incorrectly positioned, the system automatically rotates the tray 180° to ensure proper machine feeding.

3. Assembly and Labelling

• Plunger Rod presence:

  • A color camera verifies the correct plunger rod is inserted.

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  Stopper-Plunger Assembly: 

  • A backlight system checks the proper assembly of the stopper and plunger.

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  Label Presence and Position

  • Post-labeling, another camera confirms the presence and correct positioning of the syringe label.

All non-compliant syringes are identified and automatically rejected.

4. Thermoforming

Using HarleTray, three cameras inspect:

• Component Presence in Tray: The presence of all required tray components: syringe, vial, and two needles, also preventing mix-ups (for example, correct needle belongs to the correct syringe).

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  Tray Sealing Foil Code (Alucode): The linear code printed on the sealing foil to verify alignment and correctness.

• Heat Marker Label Presence: The presence of the heat-sensitive marker label on each tray, which ensures traceable heat exposure over time.

Vision System Features

• OCV Multipurpose: Enables multi-format inspections with fast and accurate defect detection.

• HarleTray: Specialized for thermoformed tray inspection with integrated lightbox and code reading capabilities.

• OEM Interface Integration: Allows seamless transition between machine and vision interfaces for enhanced control and visibility.

Results

The implementation of SEA Vision’s inspection technologies delivered measurable benefits:

This project represents a significant step forward in automating syringe packaging operations. The pharmaceutical manufacturer successfully transitioned from semi-automated processes to a fully integrated vision inspection solution. The collaboration with SEA Vision resulted in a packaging line that ensures component integrity, precise labeling, and end-to-end inspection—all within a compliant and future-ready framework.

From Manual Checks to Fully Automated Inspection

SEA Vision’s OCV Multipurpose and HarleTray systems now ensure product quality from the very first step of denesting to the final tray seal—transforming the line into a benchmark of modern pharmaceutical packaging.

Learn More

For further information about SEA Vision’s OCV Multi and HarleTray solutions, visit:

• • SEA Vision OCV Multi Solution

  • SEA Vision HarleTray Solution