Japan Quality

SPECTRA HR - Japan Quality

The high-resolution SPECTRA HR product inspection system offers the highest image resolutions for high-speed evaluation. This makes it the optimal system for high demands such as those of the Japanese pharmaceutical market, which requires visually flawless products due to cultural conditions, as consumers perceive external minimal defects as serious reasons for rejection.

Das Farbsystem erkennt 16 Millionen Farben selbst im Dreischichtbetrieb bei hoher Bandgeschwindigkeit. Zudem wird für Japan Quality Produktkontrolle eine Wasserkühlung installiert, um die Kameras auf optimaler Betriebstemperatur zu halten.

Thanks to the high resolution and constant camera temperature, the smallest soiling and blemishes can be reliably detected.

Inspection criteria and objects

Inspection objects:

  • Tablets
  • Oblongs
  • Dragees
  • Hard and soft gelatine capsules
  • Special forms
  • Sealed products

Examination criteria:

Smallest contaminants such as e.g.

  • Painting defects
  • particles on the tablet or lacquer
  • Surface defects

Additional examination criteria:

  • Colour
  • Presence
  • Size
  • Shape
  • Position
  • Circumference
  • Fragments
  • Overfill
  • Serial defects

Advantages of the Japan Quality application

Hardware and software are selected with the demands of the Japanese market in mind. Japanese goods in general are subject to very high standards of uniformity and standardisation. The consumer’s critical eye, thus sharpened, also questions the correctness of the processes and thus the product as such in the case of external flaws. Thus, the appearance of the product becomes just as decisive a criterion for producers for the Japanese market as harmlessness and efficacy.

As a result, the following characteristics become grounds for rejection:

  • Paint defects
  • Particles on tablet or lacquer

 

Critical quality defects requiring a recall:

  • Contamination with hair
  • Contamination with non-production particles

Software adaptations for Japan Quality Inspection

The software works in real time thanks to the use of QNX®. All functions can be used simultaneously – without any loss of speed. Outstanding software functions, such as production and format documentation, comprehensive audit trail, easy-to-understand menu-guided operation.

Since even the slightest reflections are problematic during product inspections in Japan Quality, the measuring line enables reliable and reproducible adjustment of the W-LED illumination. The measurement line can also be used vertically when the camera images of several cameras are displayed
are displayed one below the other.

Camera-specific colour tolerances have a negative effect on the colour evaluation. The software feature “Colours per camera” ensures that the colour values are defined separately for each camera during teach-in in order to capture these camera-related deviations and enable accurate evaluation. The operator works comfortably on a single image.

The presence of a hair is recognised by the system as foreign colour and leads to ejection. The detection performance depends on the inspection area and resolution. A product with minimal contaminant such as paint defects or flaking is reliably detected and ejected by SPECTRA HR.

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Applikationsspezifische Hardware

Um die Auswertung zu beschleunigen, übernimmt der scanware Framegrabber Aufgaben der Bildvorverarbeitung.
Die Kaskadierung mehrerer Kameras ist Bedingung für das Erreichen der benötigten Auflösung. Der von scanware entwickelte Multiplexer setzt die gewonnenen Bilder zusammen, sodass die Auswertung auf einem einzigen Bild erfolgt.
Der Einsatz einer Wasserkühlung sorgt dafür, dass die Kameras auch nach längerer Laufzeit konstant dieselben Ergebnisse zeigen wie bei der Qualifizierung. 

Um die Auswertung zu beschleunigen, übernimmt der scanware Framegrabber Aufgaben der Bildvorverarbeitung.
Die Kaskadierung mehrerer Kameras ist Bedingung für das Erreichen der benötigten Auflösung. Der von scanware entwickelte Multiplexer setzt die gewonnenen Bilder zusammen, sodass die Auswertung auf einem einzigen Bild erfolgt.
Der Einsatz einer Wasserkühlung sorgt dafür, dass die Kameras auch nach längerer Laufzeit konstant dieselben Ergebnisse zeigen wie bei der Qualifizierung.

Further application levels of SPECTRA HR

Post-Seal Product Inspection in Japan Quality

Inspection from below and after sealing can also be easily implemented with SPECTRA HR. The illumination is adjusted with side light and matching backlight to minimise reflections.

This successfully detects the following defects:

  • Tablet powder even on the underside
  • Foreign bodies on the foil

Technical data - Hardware

Camera

  • 3 CMOS, JAI
  • Camera Link interface for low-interference data exchange of large amounts of data 
  • Camera resolution: 3x 2064 x 1544 pixels / 3x 3.2 Mpx
  • Colour resolution in 16 million colour shades
  • Installation of 2 to 6 cameras