A leading pharmaceutical manufacturer engaged EAD to find a solution for a pharmaceutical vial tray packaging line where missing product frequently resulted in commercial order fulfillment failure.
The packaging line handled approximately 55 trays per minute with human quality assurance visual checks. The line had historically incurred a high number of order rejections due to missing vials.
Using vision systems and laser measurement tied into the machine programmable logic controller (PLC), EAD specified, designed and programmed a viable solution that minimized rejects to an acceptable level. The limitations of the vision system’s performance with different colors of vial labels resulted in this project being particularly challenging.
EAD worked closely with the client to ensure the solution met production, quality, maintenance and FDA standards. The commissioning phase of this project was a classic opportunity for EAD to demonstrate their dedication to making sure a job is done right by verifying the performance of the system for packaging runs with products requiring different vials, labels and speeds for several weeks after initial validation of the system on its primary product.