Fully Automatic Vial Testing Station

The fully automatic inspection system for plastic vials is an important, integrated sub-process within the automated packaging and inspection line. By combining state-of-the-art image processing and precise camera technology with stringent cleanroom standards, even difficult-to-detect defects such as “waves” on the vial surfaces are reliably detected – at maximum speed while maintaining consistent product purity. This solution sets new standards in efficiency, safety, and quality for the entire line.

The Project

The challenge lay in inspecting plastic vials for damage with the utmost precision – especially given the extremely delicate, transparent nature of the containers. In addition to a 360° all-around inspection, the base and top of the vials also had to be thoroughly checked for microscopic defects. This inspection process is a key sub-process within a highly complex system, implemented in a strictly controlled cleanroom environment.

The production cell comprises an injection molding cell of cleanroom class ISO 5 and an assembly zone of class ISO 7. Immediately after injection molding, the fragile vial body is sealed with a stopper to prevent any contamination.

The Solution

To reliably inspect the transparent plastic vials, the system is equipped with over 28 high-resolution cameras, which ensure complete coverage at various stations. Special lighting and X-ray systems make it possible to reveal otherwise barely visible damage – a technical feat with varying diameters and heights. A universal changeover kit ensures quick format changes. 

This fully automated stainless steel system operates with an impressively short cycle time of 1.5 seconds per vial and ensures that no scratches or contamination occur.

This solution combines uncompromising quality assurance with a well-thought-out cleanroom concept and high productivity – an innovation that sets standards in plastic vial testing.