Pharma

High-Speed Blister Pack Cavity Inspection

EVS is installed directly on blister scanning lines, where high-resolution line-scan cameras inspect every individual cavity at full production speed. The system detects broken or cracked pills, missing tablets, incorrect fill levels, sealing defects, and foreign contamination — all without slowing the packaging line.

Each blister is analyzed cavity by cavity, ensuring that no defective product passes through to downstream packaging or dispatch. The system's advanced vision algorithms can distinguish between subtle variations in pill appearance, fill levels, and seal integrity that would be difficult or impossible to detect consistently with manual inspection.

Automatic Rejection of Defective Blisters

When a defect is identified, the system triggers an immediate alert to the line control system, which activates pneumatic or mechanical rejection mechanisms to remove the non-conforming blister from the production stream. This automated rejection happens in real time at line speed, ensuring that only compliant product continues downstream.

Rejection events are logged with timestamps, defect type, cavity position, and batch information, creating a complete audit trail for every removed blister.

Overall Equipment Effectiveness (OEE) Data Collection

Beyond inspection, EVS continuously collects Overall Equipment Effectiveness (OEE) data from the blister scanning line. The system tracks machine availability, performance efficiency, and quality rate — the three core OEE metrics — and presents them through integrated dashboards.

OEE data is collected automatically without requiring manual data entry. Production managers can view real-time OEE scores, identify performance bottlenecks, and track improvement initiatives over time.

Machine Efficiency & Downtime Tracking

EVS monitors machine operating states to calculate efficiency metrics and record every downtime event — whether planned (changeovers, maintenance) or unplanned (jams, breakdowns, material shortages). Each downtime event is tagged with duration, cause category, and timestamp.

Downtime reports highlight the most frequent and longest-duration stoppages, helping engineering teams prioritize root-cause analysis and continuous improvement efforts. By correlating downtime data with inspection results, manufacturers can identify whether quality issues are contributing to line stoppages and vice versa.

Real-Time Alerts & Production Visibility

When defect rates exceed configurable thresholds or when machine efficiency drops below target levels, EVS sends real-time alerts to operators, supervisors, and maintenance teams. This immediate visibility enables rapid response to quality or production issues before they escalate into larger problems.

Production dashboards display live line status, current OEE, defect counts, reject rates, and machine state — giving every shift team a single source of truth for line performance.

Batch-Level Traceable Reporting

All inspection results, rejection events, and OEE data are logged against specific batch numbers with timestamps, creating a complete digital record for every production run. Reports support internal quality audits, regulatory documentation, and customer compliance requirements.

Traceable reporting helps pharmaceutical manufacturers demonstrate GMP (Good Manufacturing Practice) compliance, respond to regulatory inquiries with accurate data, and continuously improve both product quality and production efficiency.

Key Benefits

• High-speed cavity-by-cavity blister inspection at line speed
• Detection of broken, cracked, or missing pills and sealing defects
• Automatic real-time rejection of defective blisters
• Continuous OEE collection — availability, performance, quality
• Automated machine efficiency tracking
• Detailed downtime recording with cause and duration
• Real-time alerts for defect rate and efficiency thresholds
• Live production dashboards for shift visibility
• Batch-level traceable reporting for regulatory compliance
• Reduced manual inspection workload and improved QA consistency