PHARMACEUTICAL AUTOMATIC/OPTICAL INSPECTION MACHINES
AUTOMATIC VISUAL INSPECTION SYSTEMS (AVI)
Pharmaceutical Automatic Inspection Machines also known as:
Optical Inspection Machines
Optical Inspection Systems
AVI (Automatic Visual Inspection)
Visual Inspection Machines
Automatic Visual Control Systems
Ampoule and Vial Inspection Machines
These are high-precision industrial equipment used for the automatic inspection of sterile, injectable, and critical pharmaceutical products.
These systems are fundamental to ensuring compliance with:
- GMP.
- FDA.
- EMA.
- ANVISA.
- EU GMP Annex 1.
- 21 CFR Part 11.
Ensuring that products are free of:
- particles.
- fibers.
- Glass.
- Contamination.
- Cosmetic defects.
- Leaks.
- Filling defects.
- Closure problems.
- Lyophilization defects.
Modern inspection machines are used in virtually the entire global pharmaceutical industry, including:
- Injectable medications
- Vaccines
- Biologics
- Antivirals
- Hormones
- Anesthetics
- Oncology
- Injectable aesthetics
- Veterinary industry
- Blood products
- Biotechnological products
TYPES OF PHARMACEUTICAL INSPECTION MACHINES
AMPOULE INSPECTION MACHINES
Applied to:
- Glass ampoules.
- Aqueous solutions.
- Oily solutions.
- Hospital medications.
- Vitamins.
- Hormones.
- Anesthetics.
- Antibiotics.
Inspections:
- Particles.
- Fibers.
- Glass.
- Cracks. - Fill level.
- Color.
- Bubbles.
- Cosmetic defects.
Classic method:
- Ampoule rotation.
- Sudden braking.
- Liquid movement.
- Optical particle analysis.
Production:
6,000 to 36,000 ampoules/hour.
VIAL INSPECTORS
Applied in:
- Vaccines.
- Biologics.
- Monoclonals.
- Antivirals.
- Insulin.
- Oncology.
- Lyophilized medications.
Inspections:
- Particles.
- Lyophilized product.
- Vial integrity.
- Cap.
- Aluminum seal.
- Leaks.
- Fill level.
Production:
6,000 to 36,000 vials/hour
PRE-FILLED SYRINGE INSPECTORS
Applications:
- vaccines.
- hormones.
- insulin.
- injectable pens.
- self-injectable medications.
- biotechnology.
Inspections:
- particles.
- flange.
- needle.
- plunger.
- needle shield.
- closure.
- system integrity.
Production:
up to 1,000 syringes/minute.
LYOPHILIZED INSPECTORS
Applications:
- vaccines.
- antibiotics.
- sensitive medications.
Inspections:
- broken cake
- melt-back
- shrinkage
- discoloration
- structural defects
INJECTABLE MEDICATIONS
- antibiotics.
- Anti-inflammatories.
- Anesthetics.
- Vitamins.
- Corticosteroids.
- Sedatives.
VACCINES
- Human vaccines.
- Veterinary vaccines.
- mRNA vaccines.
- Biological vaccines.
BIOTECHNOLOGY
- Monoclonal antibodies.
- Recombinant proteins.
- Advanced therapies.
- High-complexity medications.
HORMONES
- Testosterone.
- GH.
- Gonadotropins.
- Veterinary hormones.
- Oil hormones.
INJECTABLE AESTHETICS
- Hyaluronic acid.
- Biostimulators.
- Enzymes.
- Fillers.
- Sterile solutions.
VETERINARY
- Ivermectin.
- Animal vaccines.
- Veterinary antibiotics.
- Veterinary hormones.
- High-volume oily products.
GLOBAL MANUFACTURERS
CLASSIC HISTORICAL MANUFACTURERS
G.F. S.p.A. / Coesia
Seidenader
Brevetti CEA
Eisai Machinery
Bosch Packaging
Körber Pharma
CMP Pharma
MODERN MANUFACTURERS
Stevanato Group
Syntegon
Antares Vision
ATS Life Sciences
OCTUM
Wilco AG
Nikka Densok
Tofflon
Optel
Dara Pharma
MANUFACTURERS AND TECHNOLOGIES
G.F. S.p.A. / COESIA
Historical specialist in:
- ampoule inspection.
- vials.
- syringes.
- aseptic lines.
Models:
GF A&F.
AV-E.
AV GS.
Technologies:
- Optical inspection.
- Computer vision.
- Leak detection.
- Multiple cameras.
GF / Coesia
BREVETTI CEA
One of the world leaders in pharmaceutical AVI.
Technologies:
- AI.
- High-speed inspection.
- Leak detection.
- Particle inspection.
- Lyo inspection.
Production:
Up to 36,000 units/hour
SEIDENADER / KÖRBER
Specialists in:
- Syringes.
- Vaccines.
- Biologics.
- Intelligent inspection.
Technologies:
- AI inspection.
- Deep learning.
- MES integration.
- Low false rejection.
Production:
Up to 1,000 syringes/minute
Körber Pharma Inspection
STEVANATO GROUP
Manufacturer of high-speed inspection systems.
Lines:
MAVIS
CVT Core
Technologies:
- Up to 20 inspection stations.
- AI.
- Non-glass-to-glass handling.
- HVLD.
- HGA.
- Advanced computer vision.
Production:
Up to 24,000 units/hour
Stevanato Visual Inspection
SYNTEGON
Specialist in:
- Inline inspection.
- Integrated filling inspection.
- Vial and ampoule inspection.
Technologies:
- Optical sensors.
- Industrial cameras.
- Geometric inspection.
- Black spot inspection.
Syntegon Inline Inspection
ATS LIFE SCIENCES
PharmaScan Line.
Technologies:
- Particle inspection down to 50 µm.
- CCIT.
- Headspace analysis.
- AI inspection.
Production:
Up to 600 ppm.
ATS PharmaScan
OCTUM
Specialist in pharmaceutical syringes.
Technologies:
- Assembly inspection.
- Filling inspection.
- Packaging inspection.
- CFR 21 Part 11.
Production:
- Up to 450 syringes/minute
- OCTUM Syringe Inspection
EQUIPMENT SIZES
SMALL SCALE
Characteristics:
- Semi-automatic.
- Compact.
- Laboratory.
- R&D.
Production:
- 100 to 9,000 units/hour
Applications:
- Pilot batches.
- Pharmaceutical development.
- Small production.
MEDIUM SCALE
Characteristics:
- Automatic.
- Continuous production.
- Multiple inspections.
Production:
12,000 to 18,000 units/hour
Applications:
- National pharmaceutical companies.
- Veterinary.
- Aesthetics.
LARGE SCALE
Features:
- Robotic lines.
- AI.
- Multi-camera inspection.
- SCADA/MES integration.
Production:
24,000 to 36,000 units/hour
Applications:
- Multinational companies.
- Vaccines.
- Biologics.
- Oncology.
AUTOMATION LEVELS
MANUAL
- Human inspection.
- Low speed.
SEMI-AUTOMATIC
- Automatic movement.
- Human decision.
CLASSIC AUTOMATIC
- Optical sensors.
- Photocells.
- Automatic rejection.
DIGITAL AUTOMATIC
- CCD.
- PLC.
- Servo drive.
INTELLIGENT AUTOMATIC SYSTEMS
- AI.
- Deep learning.
- Analytics.
- MES integration.
- Electronic traceability.
TECHNOLOGIES USED
CLASSIC TECHNOLOGIES
- Photocells.
- Halogen.
- Analog systems.
- Simple optical sensors.
MODERN TECHNOLOGIES
- CCD.
- CMOS.
- LED strobe.
- Servo drives.
- Computer vision.
ADVANCED TECHNOLOGIES
- Artificial intelligence.
- Deep learning.
- 3D vision.
- Analytics.
- Machine learning.
INSPECTION METHODS
DYNAMIC INSPECTION
- Rotation.
- Braking.
- Particle movement.
COMPUTER VISION
- Multiple cameras.
- Digital analysis.
- Optical algorithms.
DEEP LEARNING
- Continuous learning.
- Intelligent analysis.
- False reject reduction.
LEAK DETECTION
- HVLD.
- Vacuum.
- Laser.
- HGA.
HEADSPACE ANALYSIS
- Container integrity.
- Internal gases.
- Sterility.
DEFECTS DETECTED
PARTICLES
- Glass.
- Metal.
- Fibers.
- Rubber.
- Crystals.
COSMETICS
- Scratches.
- Stains.
- Deformations.
- Bubbles.
FUNCTIONAL
- Leaks.
- Failure to close.
- Incorrect level.
- Missing components.
LYOPHILIZED
- Broken cake.
- Melt-back.
- Shrinkage.
INDUSTRIAL PRODUCTION
Low Production:
100 to 9,000 units/hour
Medium Production:
12,000 to 18,000 units/hour
High Production:
24,000 to 36,000 units/hour
Ultra High Speed:
Up to 1,000 containers/minute
INTEGRATION INTO PHARMACEUTICAL LINES
Inspection machines are typically positioned after:
- filling.
- sterilization.
- lyophilization.
and before:
- labeling.
- cartoning.
- final packaging.
Integrated with:
- SCADA.
- MES.
- ERP.
- serialization.
- GMP traceability.
TECHNOLOGICAL TRENDS
- Pharmaceutical AI.
- Deep learning.
- Aseptic robotics.
- Pharma 4.0.
- Real-time analytics.
- Total digital integration.
- Gene therapy inspection.
- Nanoparticle inspection.
- Complex biologicals inspection.
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