A Look At Pharmaceutical Inspection Machine Advanced Technologies

By Dipak Mahajan and Sampatkumar Govind Donthula, MarketsandMarkets

Pharmaceutical and biotechnology companies are experiencing a rising number of inspection checkpoint mandates, a rising number of product recalls, a rise in outsourcing of manufacturing operations to emerging economies, and rapid increases in technological advancements such as loT, ML, and Al. As a result, pharma and biotech companies are increasingly using pharmaceutical inspection machines with advanced technologies.

In this article, we’ll share a technology analysis from our new market research. Key technologies are pivotal innovations driving the core functions of a system or industry. Complementary technologies enhance or support the key technologies, filling gaps or enhancing their capabilities. Pharmaceutical inspection machines integrate key technologies such as machine vision, X-ray, and laser inspection. Complementary technologies include advanced sensors and imaging techniques, robotics and automation, and Al. The convergence of these technologies drives pharmaceutical inspection machines toward unlocking their potential in inspecting products.

3 Key Technologies

Machine Vision Technology

Machine vision technology is one of the leading technologies in pharmaceutical inspection machines. Unlike conventional manual inspecting techniques, machine vision employs cameras and computer algorithms to automate visual inspection and analysis processes. This streamlined process facilitates the accurate detection of defects, measures dimensions, and verifies assembly processes, improving efficiency and product quality in the pharmaceutical industry. It ensures correct labeling, packaging integrity, and the absence of contaminants in drugs and medical devices. Machine vision systems are now integrated with Al to support pharmaceutical companies in detecting contaminants, identifying defects, ensuring consistent fill levels, minimizing consumer risk, and enhancing overall product quality through AI-driven vision inspection technology.

Examples:

• Antares Vision Group unveiled its first automatic inspection machine for blow-fill-seal (BFS) cards in 2024. Providing 100% inspection, the VRI for BFS Cards can provide quality assurance at speeds of up to 100 pieces per minute.
• FILTEC launched a new remote vision inspection system in 2022. The technique offers fast, automated, cost-effective analysis.

X-Ray Inspection Technology

X-ray inspection technology represents a pioneering technique in pharmaceutical inspection machines. It utilizes X-ray radiation to penetrate and analyze objects, enabling nondestructive testing and inspection across various industries. This technology effectively detects foreign particles, verifies correct fill levels in containers, and ensures accurate tablet placement within blister packs. X-ray systems can identify defects such as broken tablets, metal or glass contaminants, and packaging inconsistencies without compromising product sterility. X-ray inspection technology excels in rapid and efficient examination, maintaining high production throughput while ensuring top-tier quality.

Additionally, it provides detailed data for quality assurance and regulatory compliance documentation.

Examples:

• Anritsu recently introduced the newest addition to the XR75 product line, the DualX+ Dual Energy X-Ray. The DualX+ is equipped with a newly developed X-ray sensor that elevates detection capabilities when challenging applications require the highest levels of sensitivity. 
• In September 2022, Mettler Toledo launched a high-quality X-ray technology, namely, DXD and DXD+ dual energy detector technology, to detect hard-to-find foreign contaminants, such as calcified bone, low-mineral glass, rubber, and some plastics.
• Also in 2022, Mettler Toledo launched an X-ray inspection solution with high sensitivity in the Pan-Asia market. The X12 is equipped with Mettler Toledo's Contam Plus X-ray inspection software algorithms, which enhance detection capabilities for a wide range of contaminants.

Laser Inspection Technology

Laser inspection is an innovative technology that utilizes laser beams to precisely measure dimensions, verify fill levels, and detect surface defects such as cracks or contamination in vials, ampoules, blister packs, and tablets. The high precision and accuracy of laser inspection technology identify defects that traditional methods might miss, enhancing product safety and efficacy. This process involves rapid and efficient inspections, maintaining high production throughput while upholding quality standards. Additionally, it generates detailed data essential for quality control and regulatory compliance, making laser inspection an indispensable tool in pharmaceutical manufacturing.

3 Complementary Technologies

Advanced Sensors And Imaging Techniques

Sensor and imaging technologies play a pivotal role in advancing pharmaceutical inspection machines. With high-resolution sensors, pharmaceutical inspection machines can now detect even the smallest defects, which is vital for sectors such as electronics, pharmaceuticals, and aerospace, where precision is paramount. Multi-spectral and hyperspectral imaging techniques extend the capabilities of pharmaceutical inspection machines, aiding applications in agriculture, pharmaceuticals, and security by uncovering hidden materials and substances.

Robotics And Automation

Robotics and automation are important in enhancing the inspection machine's capabilities, efficiency, and overall performance. Automation reduces human error and increases throughput. Automation streamlines the inspection processes by orchestrating the flow of products through the inspection line, optimizing workflow, and minimizing bottlenecks. Automated conveyors, robotic pick-and-place systems, and robotic vision-guided systems facilitate the seamless movement of products, ensuring timely and efficient inspection. Moreover, these help integrate advanced technologies such as Al and ML into inspection systems. Al-powered algorithms can analyze vast amounts of inspection data, identifying patterns and anomalies to improve defect detection and optimize inspection parameters, which ultimately enhances the accuracy and reliability of inspection results while reducing the need for manual intervention.

Artificial Intelligence

Artificial intelligence (Al) has revolutionized inspection machines within the pharmaceutical sector, substantially boosting companies’ capabilities, efficiency, and precision. Al-powered inspection systems utilize advanced image recognition and deep learning algorithms to detect defects and anomalies with unparalleled accuracy compared to traditional methods. These systems excel at identifying complex patterns and subtle defects, often missed by human inspectors or conventional technologies. Al automates the classification of defects, distinguishing between various types such as cracks, discolorations, and contamination. This automation improves defect identification and significantly reduces false positives, enhancing productivity and minimizing unnecessary rejections.

Companies across the pharmaceutical industry are investing significantly in Al to enhance inspection experience. For instance, in April 2023, Switch On (India) raised $4.2 million through a funding round led by a Singapore-based fund to expand its Al-enabled vision inspection system platform.

Pharmaceutical Inspection Machine Companies

The top 16 companies offering pharmaceutical inspection machines are:

• Syntegon Technology GmbH (Germany)
• Körber AG (Germany)
• Stevanato Group (Italy)
• Mettler Toledo (Switzerland)
• Optel Group (Canada)
• Cognex Corporation (U.S.)
• Jekson Vision (India)
• ACG (India)
• Antares Vision S.P.A. (Italy)
• Brevetti CEA SPA (Italy)
• Omron Corporation (Japan)
• Roquette Frères (France)
• Tofflon Life Science (China)
• Proditec (France)
• Wipotec GmbH (Germany)
• CMP Pharma S.R.L. (Italy)

The global pharmaceutical inspection machines market is projected to reach $750 million by 2029, from $580 million in 2024, at a CAGR of 5.1% during the forecast period, according to our market research.

About The Authors:

Dipak Mahajan and Sampatkumar Govind Donthula are research managers at MarketsandMarkets.