This case study outlines a collaboration between SEA Vision and a leading pharmaceutical manufacturer to enhance the quality control of inhalers in their French production facility.

The focus of the project was to address critical quality features such as foreign body detection, cap color accuracy, dose counter verification, and label compliance. SEA Vision’s OCVmulti system was integrated into the production line’s labeling machine to ensure consistent product quality.

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Introduction

Inhalers are vital devices for managing respiratory conditions, and maintaining their quality is critical for patient safety. To meet stringent regulatory and safety requirements, the pharmaceutical manufacturer needed a robust quality control solution for their inhaler production line.

The objective was to tackle key quality challenges, including the detection of foreign particles, cap presence and color consistency, dose counter accuracy, and label verification.

This case study explores how SEA Vision’s OCVmulti system was implemented to address these challenges effectively.

Challenge

To maintain high-quality standards in inhaler production, it was necessary to prevent any issues that could compromise patient safety or regulatory compliance:

• Foreign Body Detection: Ensuring no contaminants, such as dust, plastic fragments, or other particles, are present in the actuator to prevent any impact on inhaler performance and patient health.
• Cap Presence and Color Consistency: Verifying that the correct cap is applied and that it matches the intended color for proper identification and brand consistency.
• Dose Counter Accuracy: Monitoring the dose counter to ensure it reflects the accurate number of doses remaining. Any inaccuracies in the dose counter could lead to incorrect dosing, potentially compromising patient safety.
• Label Presence and Verification: Ensuring that labels are correctly placed and that the data matrix code is accurate for product traceability and regulatory compliance.

These checks are essential to ensure that the inhalers are safe, functional, and compliant with regulatory standards. Any inconsistencies in product quality could lead to recalls, patient harm, or regulatory consequences.

Solution Implementation: OCVmulti

SEA Vision deployed its OCVmulti system, a comprehensive vision inspection solution, integrated into the BL-H235 labeling machine on the inhaler production line. The system was specifically configured to address the following inspection points:

• Foreign Body Detection: The first camera inspects the interior of the actuator for any particles or debris that could compromise safety.
  
• Cap Presence and Color Verification: The second camera checks that the cap is correctly placed and that its color matches the product's design.
  
• Dose Counter Accuracy Check: The third camera verifies the accuracy of the dose counter, ensuring that the displayed dose count is correct.

• Label Presence and Data Matrix Verification: The fourth camera ensures that the label is applied correctly and that the data matrix code is accurate for traceability.

The OCVmulti system is controlled via a HMI, with a touch-optimized display and provides real-time feedback, allowing operators to make quick adjustments, improving overall production line efficiency.

Conclusion

The successful implementation of SEA Vision’s OCVmulti system enhanced the quality control process for inhaler production, addressing critical challenges like foreign body detection, cap color verification, dose counter accuracy, and label compliance. This case demonstrates how advanced vision inspection systems can be tailored to meet the specific needs of pharmaceutical production, ensuring both operational efficiency and product quality.

Learn More

For further information about our Vision Inspection Systems, visit:

• SEA Vision Vision Inspection Systems