Pharmaceutical Vision Inspection
At "Kamada"
Automated Visual Inspection for Pharmaceutical Packaging
Replacing sample-based inspection with an integrated machine-vision system at "Kamada"
Client: Kamada
Location: Beit Kama, Israel
Application: Pharmaceutical packaging inspection
System: Automated flip-off cap presence inspection
Project Summary
At Kamada's pharmaceutical production facility, sample inspections identified cases in which the transparent plastic flip-off cap was missing from packaged vials.
To move from sample-based inspection to automatic inspection of every package, CrystalVision developed and integrated a machine-vision system directly into the existing packaging equipment.
A compact smart camera was installed at a point where the carton is still open and the vial can be viewed from above. The system checks whether the flip-off cap is present and, if a missing cap is detected, automatically stops the machine and generates an alert.
CrystalVision delivered the complete vision and machine-integration solution, from imaging and software to mechanical and electrical integration.
The system was configured for two vial sizes and has remained in production use. In 2024, Kamada expanded and upgraded the inspection system, commissioning CrystalVision to integrate an additional camera and update the solution.
The Challenge - Inspecting Every Package
Kamada's existing quality process relied on sample-based visual inspection. The goal was to inspect every package automatically while integrating the new capability into the existing packaging machine without significantly changing its normal operating sequence.
Finding the Right Inspection Point
One of the first engineering decisions was where the inspection should take place.
The camera was positioned after the vial had been inserted into its carton but before the carton was closed. At this stage, the top of the vial was still visible and the inspection could be performed without interfering with the packaging sequence.
Space inside the machine was limited, so CrystalVision selected a compact smart camera and designed a dedicated mounting arrangement around the available space.
A position sensor was also integrated with the machine to indicate when the package was precisely aligned with the camera. This signal triggers the inspection at the correct point in the machine cycle.
Turning a Visual Difference into a Machine Decision
The inspection was based on a simple visual characteristic of the vial.
When the transparent flip-off cap is present, the appearance of the top of the vial is different from the appearance when the cap is missing.
CrystalVision developed the image-processing logic to evaluate this difference automatically. The original implementation analyzed the dark area visible in the center of the vial image: when the cap was missing, the dark region appeared larger.
The camera performs this visual decision automatically for every package that reaches the inspection position.
The system was configured and tested for two different vial sizes, allowing the same inspection concept to support multiple production formats.
The Imaging System
Reliable visual inspection depends on more than the image-processing algorithm.
CrystalVision selected and integrated the complete imaging setup, including the smart camera, optics, lighting and filters.
During commissioning, the camera position, lens and illumination were adjusted under actual machine conditions. Testing also included changes in surrounding lighting to confirm that variations in the production environment would not unnecessarily influence the inspection.
This was particularly important because the component being inspected is transparent and the available viewing space inside the machine is small.
The final configuration created a controlled inspection environment within the existing packaging equipment.
Integrated Directly with the Packaging Machine
The vision system was designed as part of the production process rather than as a separate inspection station.
CrystalVision supplied the electrical interface, connection box, position sensor and machine connections required to integrate the camera with the existing equipment.
When a package reaches the inspection position, the sensor triggers the camera, the image is analyzed and the cap is classified as present or missing. If a missing cap is detected, the machine stops and an alert is generated.
This allows the inspection result to create an immediate operational response rather than simply recording an image for later review.
System Expansion in 2024
After several years of production use, Kamada expanded the inspection system. In 2024, CrystalVision supplied an additional smart-camera solution, adapted the inspection software and integrated the updated configuration into the production equipment.
The Result:
CrystalVision converted a sample-based visual inspection process into an automated machine-vision system integrated directly into Kamada's packaging equipment.
The system checks the presence of the flip-off cap on each package passing through the inspection station, supports two vial sizes and automatically stops the packaging machine and alerts the operator when a missing cap is detected.
Its continued production use and later expansion demonstrate the practical value of developing a vision system around the actual machine, product and inspection requirement.
Related Solutions
Have a Visual Inspection Task That Is Still Manual?
Many production checks that rely on an operator looking for a visible difference can be automated with the right combination of imaging, lighting and machine integration.
CrystalVision develops custom computer-vision systems designed around the product, inspection requirement and existing production equipment.