Category: Applications

DMC Verification types:

• ISO –IEC6022;2000 AIM Specification
• ISO – IEC15415
• AS9132 RevA;2000BC Licence ANSI

September 2009 onwards:

• AIM DPM-1-2006 DMC Licence

Track and Trace-as driven by GS1

• Supplier/Distributor to NHS stock
• Stores to theatre
• Usage and sterilisation records

The Data Matrix

and of course the medical industries.

Unlike barcodes, Data Matrix symbols can be applied directly onto the product, and or the

Packaging. It can also be read in any orientation and can contain alphanumeric information

rather than just numbers, removing the need for a ‘look up table’ of product numbers.

The Instrument Verifier is a presentation reader designed to read 2D Data Matrix symbols on instruments, or other small items. Surgical instruments have a value that far exceeds their size, making the ability to individually track and trace each item highly desirable. With this device organizations can easily track each item while eliminating manual data entry, thus improving the speed and accuracy of costs and data collection.

Features:

• Integrated lighting and state-of-the-art optics
• Read and audible operation makes reading fast and easy
• Manufactured in SS to IP65
• Fiducial area for code positioning
• Fixed standoff
• Verification TCP/IP output available

The incidence of fake, expired, adulterated, mislabelled or otherwise unauthorized medicinal products reaching the market place is on the increase. The pharmaceutical industry itself is also at major risk. Today, it loses sales revenue to counterfeiters and product diverters. If this activity gets out of control and major tragedies happen, which it can, the resulting product recalls, brand damage and when stock price falls this will cause major financial impact at a time when drug company profits are already under extreme pressure.

Within the pharmaceutical industry the use and application is driven by Traceability and the fight against counterfeiting. Also the need to record/read expiry/use by dates at the point of saleor distribution, and where the product is subject to a quality driven recall program. The Data Matrix is a 2D symbol capable of storing a large amount of information within almost any physical size. It has wide adoption including the aerospace, automotive and of course medical/pharmaceutical industries.

Unlike barcodes, Data Matrix symbols can be applied directly onto the product, and or the Packaging. It can also be read in any orientation and can contain alphanumeric information rather than just numbers, removing the need for a ‘look up table’ of product numbers.

When you source your inline monitoring, verification and control, your inline readers and your SCADA software from an experienced specialist solution provider such as MVT, you can be assured of a robust and reliable long term traceability solution.

The Data Matrix is a 2D symbol capable of storing a large amount of information within almost any physical size.

Benefits

• Data Matrix can carry 25 to 100 times more information than typical bar code:
  3116 numeric, 2335 alphanumeric characters or 1556 bytes of binary information.
• 6 error correction schemes to allow recovery from symbol damage.
• Round dots or square cells from almost any type of print device: Inkjet, Etch, Dot Matrix, Pin Stamp, Thermal Transfer, Pad Print, Laser Print, and Web Press

Methods of applying the code

• Laser – high speed, high quality permanent marking
• Continuous Inkjet – Non-permanent ink based system ideally suited for high speed applications
• Indent/dot peen – Permanent ‘impact’ marking on metal and plastic components
• Print and Apply Thermal – Thermal printing systems with automatic inline applicators

Typical readers

Reading and Communication – MVRC

MVT/Siemens covers all four key elements with a variety of products, systems, and provides support for the creation of applications.

• Marking: Marking a product is normally done very early on in the production process so that all following steps can be controlled using the product identity. Marks are often applied to parts with a method called Direct Part Marking (DPM).
• Verification: By using verification systems, the readability of marks is guaranteed throughout the entire production process regardless of any possible contamination or when using different read devices. Also the marking can still be read after the production process, throughout the life span of the product.
  For example, the SIMATIC HawkEye 1500 series provides the capability to monitor marks in real-time with its DPM verification options. The Measuring code quality results in cost reductions due to marking cycle time optimization, with the prevention of plant downtimes and the prevention of additional handling effort. The Vision Sensor VS130-2 is outfitted with a function that can measure code quality according to the AIM standard.
• Reading: In order to ensure user friendliness and secure functioning, the readers must exhibit great flexibility regarding design, interfaces, etc. Only then is it possible to satisfy the needs of many different industrial sectors. The SIMATIC line of products, consisting of the compact HawkEye 1500, the Vision Sensor VS130-2 with separate sensor head, and the mobile HawkEye readers, cover all these requirements.
• Communication: The communication between reading device and process control is performed by a host of possible standard interfaces, for example by PROFIBUS, PROFINET, Ethernet, RS232 and by expandable digital inputs and outputs. These interfaces handle the secure transmission of the trigger signal and also the fast and reliable transmission of the reading results.

Below is a table of typical 2D code and their features:

Not only can we develop vision applications fast, we use the industries leading software, built on layers of many years of machine vision software

For customers needing automated inspection for the factory floor or for other simple vision tasks without the need for programming, Machine Vision Technology supply a range of complete vision systems that are simple to install and set-up. These range from the simplest task oriented ‘Vision Appliances’ through to configurable vision systems capable of more involved vision applications. These vision systems all have very simple user interfaces that guide the user through the process of creating an inspection application.

Cognex – PatMax Tool for patterns, matching and sorting
If you are familiar with machine vision, you will know how difficult it can be to sort different parts, especially when the parts look similar, are touching or overlapping each other. PatMax can eliminate this confusion by using the tool to locate and accurately identify each part. Even if the appearances of the parts vary, reliable sorting is achieved every time and this with a single accept threshold for all different identified parts.

IPD Vision Appliance- Label alignment, placement and quality.
As part of a family of IPD Vision Appliance products, iLabel is an automated ‘Vision Appliance’ that rapidly checks the placement and quality of labels on bottles, boxes, cans and other rigid, packaged goods. The interface screens, which are customized for a label inspection process, enable you to specify areas to inspect, define tolerances for position and rotation, and set thresholds to pass, recycle or fail the label. When these simple steps are done, iLabel uses a proprietary neural net technology to automatically learn what a good label looks like. Once trained, all of these parameters can be saved on the Vision Appliance, or on a network, so that the same inspection solution can be used across multiple manufacturing lines.

Sherlock

Sherlock is a vision application software development environment that simplifies the creation and deployment of a wide variety of machine vision tasks including inspection, packaging, tracking and quality control. Sherlock is available in two versions to support your individual application needs and budget.

Sherlock Essential contains the commonly used machine vision features. Sherlock Professional contains our full suite of machine vision software tools.

There is a huge menu of capabilities to meet your needs:

• Pattern recognition
• Image analysis
• Measurement and gauging
• Regions of interest-line, arc, circle, rectangle, point, and spoke.
• In line scripting and landmark
• Image recording and Playback
• And others

Capsule inspection prevents: Accidental product mixing. Incorrectly marked dosage values reaching customers. Shipping of faulty capsules to customers.

• 500 – 1000 per minute
• OCR and OCV of print
• Quality control of surface defects.
• Quality control of contamination and bubbles.
• Comprehensive screen display including live images
• Simple product changeover

Hardware and Software Specification

• An industrial Vision system with CFR21 part 11 approved software.
• A bulk hopper and Bowl Feeder in SS and FDA approved polyurethane sprayed. This out-puts onto a conveyor, with rotation, and a reject sort facility. With double speed progressive scan cameras and lighting mounted along the conveyor.
• Interchangeable conveyor belts for product cleanliness.
• All product contact material is 316L stainless steel FDA approved.

Blister Pack Inspection is also available.

OCR (Optical Character Recognition) and DataMatrix (2D barcodes) are two techniques by which products or components can be identified by a vision system. These are known as automatic identification methods.

MVT has a great deal of experience in both, having carried out OCR with machine vision systems on fast-moving, variable fonts in multiple industry sectors. With our expertise we are able to perform many checks per second.

DataMatrix are visual codes that can be read and decoded by machine vision systems. The increasing use of data matrix codes is linked to the aeronautical, automotive and semiconductor industries’ requirements for ‘traceability’. The intention is that batch or serial numbers can be permanently marked onto components. This is useful for tracking defective batches and also identifying counterfeit parts.

DataMatrix marks are designed with a degree of built-in redundancy so that damage to the mark does not necessarily make it unreadable. Some customers choose to mark products directly (laser-marked, moulded, dot-peened etc) while others prefer to use it as an advanced code on a label, where it can store much more information than a similar-sized barcode. DataMatrix can also hold alphanumeric information rather than just numeric, meaning that there is no need for a look-up table of values.

MVT can provide datamatrix readers and advise on how data matrix could help your industry.

• Data Matrix can carry 25 to 100 times more information than typical bar code: 3116 numeric, 2335 alphanumeric characters or 1556 bytes of binary information.
• Designed to survive harsh industrial environments: 6 error correction schemes to allow recovery from symbol damage.
• Round dots or square cells from almost any type of print device: Inkjet, Etch, Dot Matrix, Pin Stamp, Thermal Transfer, Pad Print, Laser Print, Web Press

Benefits

• Permanent product identification,
• Serial/batch number marked for the life of the product,
• Security & counterfeit prevention.

Based on experiences and feedback from the food and labelling industries, MVT has developed a label checker to meet the food industry’s stringent requirements:

The continual drive from supermarkets for improved quality, 100% error free labelling and reduced costs is resulting on an increased burden on suppliers.

At Machine Vision Technology we are helping our customers to not only meet these demands but to also reduce unit costs via our automated label checking system.

Removing the need for the human element in label checking also enables you the customer to use end of line automation such as automatic case erection and packing, thereby further reducing the unit costs.

Benefits

• Eliminates operator error and enables operator-free end of line automation
• Automatically detects incorrect labels, printing errors & poor quality print
• Fast – typically 200 labels or 600 codes per minute on moving production lines
• Easy to use windows interface
• Factory proven rugged hardware and software
• Stainless steel IP65/6 for harsh environments including food and pharmaceutical
• Unbeatable benefit / cost ratio from a company with a proven track record.

Capabilities include:

• Foreign debris in the pocket (metallic, non metallic, bugs etc.).
• Missing tablets.
• Wrong shape tablets.
• Tablet’s position.
• Cracked tablets.
• Scratched or broken tablets.
• Pinhole detection on the PVDC foil.
• Print defects.
• Hair or fibers sealed between the PVDC and the aluminum foils.
• Foreign objects sealed between the PVDC and the aluminum foils.
• Blister incomplete cutting.
• Print defects such as embossing.
• Scratched or dirty pockets. (under development)
• Deformed pockets. (under development)
• Torn pockets. (under development)

Operation

The automatic blister (32x84mm) inspection machine consists of a regular speed blister feeder that loads the blisters on a conveyor that distributes them on 2 other sideline conveyors bringing the blisters along the different control stations. Both sides of the blister are inspected.

Once the inspection is completed, rejects are segregated and collected at a waste station. All control stations are connected to the machinery bearing structure in such a way that line operator’s access meets all safety and cleaning requirements. A machine management PLC operates the machine and manages input and output signals from the different control stations and handle the rejects station. The complete machine is GMP compliant.

There are four Vision Inspection Stations

Station 1 inspects the blister from the pocket side. The lighting system consists of white high luminosity leds (for stability and life-span) combined with a dedicated light diffuser that sheds homogenous and diffused light on the object under inspection. The camera is positioned vertically above the blister, at a distance of 200 mm from bliste level, which produces a framing field of 90×70 mm. For performance purposes, it uses a color, high resolution (1600×1200 pixels) camera.

Station 2 inspects pocket deformation and detecting ripped pockets, using light reflection. The white led illuminator projects light onto the blister under inspection, from an angle of 45°. The camera that frames the blister is also positioned at 45° with respect to the reference perpendicular, so that the light it receives comes from the most external pocket area.

Station 3 inspects the print on the side of the aluminum cover. The visual configuration is similar to the S1 Station system, but here the 1600×1200 pixel resolution camera is black and white, since no relevant color detail is to be examined. For Print defects the lighting system has to cater with the highly reflecting aluminum foil surface affecting control quality. This same camera will also carry out the pocket sealing inspection

Station 4 inspects the lateral embossed type of printing. The visual configuration is similar to the S2 Station system; here the 640×480 pixels resolution camera is black and white.

Verify codes in production with this high speed code reader. Ideally suited to reading cans, since it can read codes in any radial orientation.

The system is designed to read the recipe code of every item at line speed and take appropriate action on detection of bad items. The code can comprise up to five unique alpha and numeric characters.

This means it can be installed at any point on the line, typically after the ink jet head, product filling and or labelling. This ensures correct product identification.

The system can then include label reading, either bar codes or patterns, thus ensuring integrity of labels to product.

Features and benefits

• “Can Speed” up to 1200 cans per minute
• Auto reject incorrect codes
• Floor mounted with line height variation adjustment
• Comprehensive screen display including live images / last “bad” can
• Simple product changeover (keyboard entry / or automatic from factory system)
• Enclosures in stainless steel to food industry standards

The system is to interrogate the top of every can utilising 3D technology at line speed. Eliminating your weakest link.

This Solution Prevents:

• Faulty seal products entering cookers
• Damaged cans jamming lines and Cookers
• exploding cans

Benefits

• Fault detection side of 0.10mm
• System resolution of 0.050mm

This means it can be installed at any point of the line, typically after product fitting prior to the cooker/sterilizer.

• Can speed up to 1000 per minute
• With or without gap
• Conveyor mounted with line height variation adjustment
• Simple product changeover (Keyboard entry or automatic from factory system)
• enclosures to food industry standard IP66 rated
• Interfaces to line to operate mechanism

We can implement Quality Control of surface defects such as cracks and chips. For transparent capsules, or soft gel type, we can also check for bubbles and contamination. We have the ability to confirm the presence of logos and dosage values, including the presence and position of drug release holes. All this prevents accidental product mixing, or incorrectly marked or faulty product reaching your customer.

Hardware and Software Specification.

The specification of a tablet inspection system is as follows:

• A 600mm diameter bowl feeder in Stainless Steel and a variable speed controller.
• A speed of 800 – 1000 tablets per minute
• Outputs onto a conveyor with a reject sort facility.
• With up to four double speed progressive scan cameras and lighting mounted along the conveyor.
• A high speed P.C. with a 17 inch LCD display mounted in a S.S. enclosure.
• The system is designed to Pharmaceutical standards
• The software complies with FDA requirements, all documentation is to CFR 21 pt 11, with the fully validated version option.

Vision Tablet System Ability

The vision tablet system abilities include:

• Can check both flat and convex tablets
• Presence and quality check of multiple characters stamped in both surfaces using OCV (Optical Character Verification)
• Check for surface defects such as chips, protrusions and bubbles
• Check the top / bottom face plus the two sides and as much as the ends as possible.
• The length of a capsule or tablet can be up to a maximum of 27mm.
• The maximum tablet or capsule width, or maximum diameter for a round tablet, is 15mm with 5 mm as the minimum.

All our tablet inspection systems come with installation and on site commissioning, then twelve months warranty. This includes telephone and on site support.