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Preparations - Vials

Vials are a test object that are inspected individually, together with syringes, carpules or ampoules in a mixed blister (tray) or on the labelling machine. They can be filled with solids or liquids, usually in fill quantities up to 200 ml. The vials are closed either with rubber stoppers or aluminium caps with included piercing membrane (piercing vial).

Object-specific challenges

Packaging features

The majority of vials in the medical sector are made of glass. Therefore, deviations in shape as well as staining may occur. Here, inspection of the vials before filling is a possible option.


Packaging process

Shaking and movement of the machine belt can cause bubbles and foam to form in liquids in the vial. This can affect the detection of the fill level.


Optical criteria

If the camera is not directly above the vial, optical distortions may occur. These are compensated for, for example, by camera positioning, distortion-free lenses or software to avoid incorrect ejection.


Product features

Vials with liquid contents may contain particles in the solution. This is usually inspected during filling to avoid rejects at an early stage and thus improve productivity.

Recommended system for the inspection of vials

The most common inspection task that scanware performs on vials is the inspection of the presence of the cap and the integrity of the vial in the same step, as well as the presence of the label in the tray. For you as a customer, the artificial intelligence-based system for parenterals PATERA offers the perfect solution.


Highlights of the PATERA Parenterals inspection system

  • Fast product changeover with maximum inspection reliability, as label and vial are inspected in one step
  • Software optimised for mixed blisters: vials with solid content and ampoules with associated solvent ampoule can be taught and inspected together
  • The user interface is easy to use and customisable to the operator in your company. This includes automatic learning, Alert View – central placement of system messages – and gesture control.
  • High-quality colour recognition with up to 2,100 images per minute in up to 16 million colours can reliably inspect even the most demanding product-tray combinations

Inspection criteria

The following criteria can be inspected:

  • Presence of the cap
  • Colour of the cap
  • Parallel presence and colour of the label in the same inspection step

Alternative inspection task

The SIGNUM Print system can be used for the inspection of codes and plain text on the label for individual inspection on labelling.

Serialisation of data on labels as well as aggregation of bottles and package inserts in folding boxes, bundles and cases is possible with Track & Trace solutions of the CAPA series and IMPERA Line Management in combination.

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Further preparations from scanware

Inspecting the presence, integrity and quality of the ampoule's ring code.

Inspection of the presence and colour of the cap and the presence of the label.

Solutions for the optical inspection of fragmented and broken lozenges.

Special algorithms for position at high oblongs increase productivity.

Inspection before or after sealing, reflections are compensated.

Software based on artificial intelligence for the inspection of syringes.

Inspection of the active ingredient patches to check size, position and packaging.

For hard gelatine capsules scanware offers a range of specified test parameters.​

Three-dimensional inspection excludes missing layer and offers highest safety.

3D inspection for powders in very small quantities with specially developed algorithms.

The coating is often subject to chipping, which is detected with high evaluation accuracy.

Solutions for every conceivable product and film combination as well as product shape.