This case study focuses on the implementation of SEA Vision’s OCV Multi and Harle-tray solutions on a squeezable tube packaging line in Germany. Integrated with Marchesini’s MILL200 tube filler and FB420 thermoforming machine, the solution was designed to ensure the accuracy of printed data on the tubes and tray sealing foils, as well as verify the completeness of the trays. The integration resulted in improved quality control, reduced errors, and enhanced operational efficiency for the client. 

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Introduction

A global pharmaceutical company required a reliable inspection system for its squeezable tube packaging line located in Germany. The packaging line, responsible for filling and closing squeezable aluminum tubes into single PVC trays, needed an advanced solution to ensure:

• Accuracy of non-serialized data printed on tubes and trays

• Completeness of each tray (tube, cap, and applicator cap)

• Error reduction to minimize product waste and recalls

SEA Vision provided an integrated vision inspection system combo with OCV Multi and Harle-tray technologies to meet these requirements.

Challenge

The pharmaceutical company encountered several challenges in their packaging process: 

• Non-Serialized Data Accuracy on Tubes and Trays:  Ensuring that variable data printed on both sides of the tubes and on the tray sealing foil was correct and legible. 

• Tray Completeness:  Verifying that each tray was filled with a tube, cap, and applicator cap before sealing. 

• Error Reduction:  Minimizing the rejection of incorrectly filled or labeled products to avoid costly rework or product recalls. 

To address these challenges, the company required a robust, automated inspection system that could operate seamlessly with their existing machinery. 

Solution: OCVmulti and Harletray

SEA Vision implemented a comprehensive vision inspection system, integrating the OCV Multi and Harle-tray solutions within the packaging line. The system was configured across two key stages:

Data Printing and Verification on the tube

• OCV Multi was deployed on the MILL200 tube filler to verify non-serialized variable data..

• After filling and sealing, a Domino D620i printer laser-printed variable data onto both sides of the tube:

  • Expiry date on one side

  • Batch number on the other side

• Two high-resolution micro-cameras, equipped with integrated LED lighting, inspected the printed data.

• The OCV Multi system ensured that all printed data was correctly applied and legible.

• Tubes with incorrect or illegible data were automatically rejected before proceeding further.

Tray Filling, Completeness, and Sealing Verification

• Harletray technology was used to verify the completeness of each tray.

• Two dedicated cameras ensured each tray contained:

  • A tube with a cap

  • A separate applicator cap

• Incomplete trays were automatically rejected.

• After ink-jet printing, two additional cameras checked the three lines of non-serialized variable data on the tray sealing foil:

  • Manufacturing date

  • Batch number

  • Expiry date

• Any tray with incorrect printed data was also automatically rejected.

System Integration and Additional Features

• HMI Integration: Vision inspection system fully integrated into the machine’s HMI, allowing seamless switching between OEM HMI and SEA Vision’s control panel.

• Remote Management: Enabled remote batch management via SEA Vision Server/Client, allowing users to manage operations offsite.

• Printer Management:

  • Domino D620i printer (MILL200) for applying non-serialized data on tubes

  • Wolke ink-jet printer (FB420) for applying non-serialized data on tray sealing foil

• Advanced Vision Technology:

  • High-resolution cameras with lightbox and green color backgrounds for precise component detection.

  • LED bar lights ensuring optimal inspection conditions.

  • Automatic rejection of defective trays and tubes, enhancing quality control.

Results

The implementation of SEA Vision’s OCV Multi and Harle-tray solutions on the packaging line delivered several key benefits: 

• Enhanced Product Quality: Precise inspection of printed data and tray completeness reduced the number of defective products reaching the market. 

• Increased Efficiency: The automated system minimized manual inspection, enabling higher throughput without compromising quality. 

• Error Reduction: Automatic rejection of defective products reduced errors and ensured compliance with quality standards. 

• Operational Reliability: Seamless integration with existing machinery resulted in consistent performance and minimal downtime. 

Conclusion

The deployment of SEA Vision’s OCV Multi and Harletray solutions on the squeezable tube packaging line significantly improved the accuracy and reliability of the packaging process. The automated inspection capabilities ensured that only correctly printed and fully completed trays were sealed and shipped, safeguarding the pharmaceutical company’s product integrity and brand reputation. This case study highlights the value of advanced vision inspection systems in pharmaceutical packaging, particularly for products requiring precise data verification and completeness checks.

Learn More

For further information about our Vision Inspection Systems, visit:

• SEA Vision Vision Inspection Systems