For any pharmaceutical company, ensuring the production of safe, reliable, and high-quality products is of major importance. Manufacturers and contract packaging companies of solid dose pharmaceuticals face the challenge of maintaining strict adherence to regulatory standards while striving to meet the increasing demands of the healthcare industry. In this pursuit, the integration of advanced technology such as tablet inspection cameras emerges as a game-changer, offering substantial benefits to pharmaceutical manufacturers worldwide.
Now, you can experience unrivaled product quality yourself and elevate your production standards with the advanced BottleChrom inspection system with Single Tablet Reject function. This cutting-edge technology enables identification and rejection of damaged and wrong tablets and capsules, ensuring that each bottle contains only the highest quality product.
Enhancing Quality Control
A tablet inspection camera serves as a vigilant guardian, monitoring each tablet or capsule and validating their quality based on a set of predefined parameters. By leveraging sophisticated imaging and analysis techniques, this cutting-edge system can swiftly detect even the slightest irregularities in shape, size, or color, signaling potential defects or deviations from the intended composition. Its role in quality control ensures that only the highest standard products reach the consumers.
Preventing Foreign Contamination
Foreign contaminants, whether they are extraneous particles or incorrect tablets or capsules, pose significant risks to patient and consumer safety and can tarnish a pharmaceutical company’s reputation. The visual inspection system acts as a powerful safeguard against such mishaps. Its ability to identify foreign objects with unparalleled precision ensures that only the intended products find their way into the bottles, minimizing the possibility of mix-ups and cross-contamination.
The Single Tablet Reject system that comes as an optional unit to the BottleChrom camera system, takes quality control to a new level. This ingenious device is designed to extract foreign and defective products from the product flow before entering the counting machine’s infra-red product counting channels, without affecting the overall machine output. By swiftly removing these anomalies, the single tablet reject system prevents them from reaching the filling stage and ensures that only flawless products are dispensed into the bottles.
Preserving Brand Reputation
In an era of heightened awareness and scrutiny, maintaining a strong brand reputation is critical for any pharmaceutical company. Any instance of substandard or contaminated products can have severe consequences, ranging from costly recalls to irreversible damage to a brand’s image. The tablet inspection system, equipped with a single tablet reject device, acts as a robust defense mechanism against potential quality issues. By promptly and effectively removing foreign and defective products, the system safeguards the brand’s integrity, protects patient safety, and reinforces trust in the manufacturer’s commitment to delivering only the highest quality pharmaceuticals.
How does it Work?
The BottleChrom inspection system with Single Tablet Reject unit is used to inspect the tablets or capsules that are being processed by the counting module of the Cremer CFS 622 and CFI 622 counting and bottle filling systems. Multiple full-color cameras monitor the products in real-time while they run over the vibratory plates of the counting modules. The cameras and dedicated software detect color, shape, damage, and breakage of the products. The system can differentiate between a defective product and a foreign product. A defective product can be a small product chip or a product that is damaged or broken. A foreign product is any product or object that is not supposed to be present in the product batch.
If a defective product is detected, the vibratory plates of the counting module are briefly paused while a so called ‘reject chute’ moves to its outer, “extended” position and removes the defective product by means of vacuum. The defective product is subsequently blown straight into a lockable collector drum.
If a foreign product is detected, the machine stops immediately, and an alarm message is prompted. An acknowledge button must be pressed before operation can be restarted and only by an operator with the required access rights and after the foreign product has manually been removed.
The BottleChrom with Single Tablet Reject system offers several key benefits compared to other visual inspection and monitoring systems that are available. The foremost advantage of single tablet rejection is the almost instant and on-the-fly removal or the incorrect or damaged tablet or capsule, without affecting the overall machine output. This results in real-time inspection of up to 400 qualified bottles per minute!
The camera system itself is developed by Uhlmann and is also being used on their IBC 150 integrated bottle filling center. The advanced monitoring and analyses software was developed specifically for pharmaceutical purposes.
Operational Efficiency and Cost Savings
While the primary objective of a visual inspection system is to maintain quality standards, it also offers tangible benefits to pharmaceutical manufacturers in terms of operational efficiency and cost savings. By swiftly and accurately identifying defective or non-compliant products, the camera enables proactive intervention and prevents downstream complications.
The inclusion of a single tablet reject system not only enhances quality control but also improves operational efficiency and delivers cost savings. By eliminating the need for manual intervention in identifying and removing individual faulty tablets, the system streamlines the manufacturing process, reduces human error, and increases throughput. This automation leads to optimized resource utilization, minimized rework, and ultimately significant cost savings for pharmaceutical manufacturers.
To comply with 21CFR regulations, tamper proof batch reports are automatically generated to gain full insight in production statistics which can be useful for detailed performance and efficiency analysis.
The integration of tablet inspection cameras and single tablet reject systems represents a significant leap forward in pharmaceutical manufacturing. These advanced technologies play an indispensable role in upholding the quality, safety, and integrity of pharmaceutical products. By combining precise imaging, analysis capabilities, and targeted removal of defective and foreign tablets, these systems empower manufacturers to ensure the production of reliable medicines while enhancing operational efficiency, reducing costs, and preserving their brand reputation. Embracing these advancements is not just a step towards excellence or a wise investment; it is a commitment to excellence and dedication to ensuring the well-being of consumers and the continued advancement of the pharmaceutical industry as a whole.