Pharmaceutical Packaging Inspection

AI Vision for Pharmaceutical Packaging Inspection

Detect surface defects, dimensional variance, and quality issues in vials, ampoules, syringes, and more. Reduce manual inspection costs by up to 70% while maintaining 100% GMP compliance.

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Scan result screen: a syringe barrel checked and flagged on one area — Syringe check

Comprehensive Inspection Coverage

PIQAPART delivers specialized AI vision for every critical packaging inspection point in pharmaceutical manufacturing.

01
Vials
Surface defect detection, dimensional verification, and closure integrity inspection for glass vials in liquid and lyophilized formulations. Surface defects • Dimensional variance • Closure inspection
02
Ampoules
Micro-defect and particulate detection on fragile glass ampoules with sub-millimeter precision and damage-free inspection. Micro-defects • Particulate detection • Glass integrity
03
Syringes
Automated inspection of syringe barrels, plungers, and tips for dimensional accuracy and surface quality in pre-filled and empty configurations. Barrel integrity • Plunger fit • Tip quality
04
Closures
Verify proper sealing, dimensional fit, and material integrity on rubber stoppers and plastic caps across all container types. Seal integrity • Dimensional fit • Material defects
05
Labels
Validate label presence, correct positioning, barcode readability, and print quality for full traceability and GXP compliance. Label presence • Position accuracy • Barcode readability
06
Components
Inspect needles, syringes caps, ferrules, and sub-components for dimensional accuracy and assembly readiness. Dimensional verification • Assembly readiness • Defect detection

Scan result screen: a syringe needle hub detected and passed — Needle hub

The Manual Inspection Challenge

Manual visual inspection is labor-intensive and prone to human error
100% inspection mandates increase operational costs by 40%–60%
Quality escapes and regulatory findings from missed defects
Limited scalability as production volumes grow
Compliance documentation and traceability gaps
High staff turnover in repetitive inspection roles

Limited visibility. High risk.

Two technicians in hairnets and masks working at a laboratory instrument — Clean room

AI-Powered Inspection at Scale

100% automated. Real-time feedback.

Inspect 100% of units in real-time without speed compromise
Detect defects below human visibility threshold (sub-micron precision)
Eliminate human bias and fatigue-related quality escapes
Generate audit-ready compliance documentation automatically
Integrate seamlessly with existing production lines
Reduce per-unit inspection cost by 60–75%
Scale inspection capacity without adding headcount

Proven Results

Pharmaceutical manufacturers using PIQAPART report significant operational and compliance improvements.

Reduction in Inspection Labor Costs: 70%; Reduction in Inspection Labor Costs
Defect Detection Accuracy: 99.8%; Defect Detection Accuracy
Unit Coverage (100% Inspection): 100%; Unit Coverage (100% Inspection)
Weeks to Full Deployment: 6–12; Weeks to Full Deployment

Manual vs. AI Vision Inspection

Capability	Manual Inspection	PIQAPART AI Vision
Coverage	Sample-based (2–5%)	100% inspection
Detection Accuracy	92–96% (operator-dependent)	99.8% consistent
Speed	5–10 sec per unit	0.5–2 sec per unit
Defect Types Detected	Visible defects only	Micro-defects + dimensional + dimensional
Compliance Documentation	Manual, time-consuming	Automated, audit-ready
Scalability	Requires more headcount	No additional labor
Cost per Unit (long-term)	€0.15–0.35	€0.04–0.08

How to Get Started

01
Assessment & Planning
We evaluate your current inspection process, production line specifications, and defect typologies to design a custom solution.
02
System Design & Integration
Our engineering team designs camera placement, lighting, and software configuration tailored to your exact packaging types and line speed.
03
Training & Deployment
We train your quality and operations teams, validate system performance, and handle full installation with minimal line downtime.
04
Support & Optimization
Continuous monitoring, model refinement, and ongoing support ensure sustained high accuracy and compliance.

Pharma Manufacturer Case Study

€2.1M Annual labor cost reduction
18 months ROI payback period
92% Increase in quality escapes detected vs. manual

“PIQAPART eliminated our quality escapes and cut inspection costs in half. We now inspect 100% of our vial production with zero compliance findings.”

A mid-sized European pharmaceutical manufacturer producing injectable medications implemented PIQAPART across four production lines. The system was trained on their vial and syringe portfolio within 8 weeks and achieved full operational status by week 12.

Key outcomes: Reduced inspection staff from 8 FTE to 2 FTE (monitoring/maintenance only); achieved 100% unit inspection vs. previous 5% sampling; detected 450+ additional defects in first year that manual inspection missed; generated fully compliant inspection records for FDA/EMA audits with zero findings; maintained 99.8% uptime across all four lines.

FAQ

Frequently Asked Questions

Another question? Call us on +39 049 825 6850 or email info@logirobotix.com.

Is PIQAPART GMP-compliant?

Yes. PIQAPART is validated for GMP/GxP environments. We provide full system validation documentation, audit trails, and compliance support for FDA/EMA requirements.

How does the system handle different packaging types?

PIQAPART is trained on your specific packaging portfolio (vials, ampoules, syringes, etc.). We deliver a custom model validated for your exact products and production specifications.

What about line speed and integration?

The system integrates with existing vision hardware and PLCs. We design for your line speed—typically 60–300 units/minute depending on container type and inspection complexity.

How long is the deployment timeline?

Assessment to full production typically takes 8–16 weeks, depending on line complexity and customization needs. We minimize downtime through off-line testing and pilot phases.

What about software updates and support?

We provide ongoing support, model refinement, and security updates as standard. Your system stays current with regulatory changes and evolving production needs.

Can we train our own operators?

Absolutely. We provide comprehensive training for your quality, ops, and IT teams. The system is designed for easy operation and minimal specialist knowledge.

Ready to Automate Your Inspection Process?

Contact our pharmaceutical inspection specialists to discuss your packaging quality and compliance challenges. We’ll design a solution built for your exact needs.

Free feasibility test

Test it on your line. Before you spend a euro.

Send us 20 defective parts or high-res photos. We train a model on your parts and show you detection rate, false positives and cycle time before you sign anything.

parts or photos: 20; parts or photos
days to results: 5-7; days to results
no commitment: €0; no commitment