360 Degree Syrup Cap Inspection Using DeepInspect
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Introduction
Quality control in packaging can make or break product integrity, especially for sensitive products like pharmaceutical syrups. Even minor flaws such as dents, missing seals, or improperly threaded caps can lead to leakage, contamination, and ultimately a loss of consumer trust. For pharma companies, these defects pose not only a threat to product safety but also to regulatory compliance and brand reputation.
Common Syrup Cap Defects in Pharma and Their Impact on Product Quality and Compliance
Here’s an overview of common defects on syrup caps and their potential outcomes:
DeepInspect® - FDA CFR Complaint Software for Pharma Quality Inspection
DeepInspect® is an FDA CFR-compliant, AI-powered visual inspection software designed specifically for syrup cap quality control in the pharmaceutical industry. It identifies surface defects on syrup caps with remarkable 99.5% accuracy, even on high-speed production lines. By detecting issues like dents, missing seals, and improper threading, DeepInspect® ensures that only defect-free products reaches the market, helping manufacturers maintain compliance, protect consumer safety, and uphold brand reputation.
Key Components of the DeepInspect® Setup
DeepInspect Software: The AI-powered system at the heart of inspection.
Industrial Controller: Equipped with an i5 processor and GPU for fast data processing.
Industrial Vision Lights & Camera: Ensure high-quality images for precise defect detection.
Mitsubishi PLC: Controls conveyor speed and system coordination for seamless operation.
How DeepInspect® AI- Powered Syrup Cap Inspection works?
After filling, each bottle is transferred to the capping machine on a conveyor belt, aligned in a single file to position each bottle precisely under the capping head. As a bottle arrives at the capping head, a cap is placed on its mouth, and a spindle or chuck capper twists and fastens it securely.
The capped bottle then moves to the SwitchOn DeepInspect® station, where two side cameras and one top camera provide a 360-degree inspection to detect defects such as cuts, missing seals, and dents—with 99.5% accuracy. Strategically positioned lighting enhances visibility, ensuring each camera captures clear, detailed images for a thorough inspection, so only bottles with flawless caps continue forward.
Why Choose DeepInspect® for Visual Quality Inspection in Pharma
Conclusion:
DeepInspect® offers a powerful solution for syrup cap inspection, detecting even the smallest surface defects with precision to ensure product quality. By optimizing production efficiency and reducing the need for manual labor, it streamlines operations while lowering costs. DeepInspect® consistently delivers defect-free products that meet the strictest quality standards, reinforcing brand reputation and trust in the process.
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FAQ’s :
DeepInspect uses readily available industrial-grade hardware to ensure high repeatability and long lifespan. We provide a basic kit to help you get started, which includes a controller, camera, lights, and a PLC.
DeepInspect supports inspection speeds of up to 1000 parts per minute. The final speed depends on various factors, such as the number of cameras, lighting, and other line conditions. If you have a requirement above 1000 PPM, please contact us.
DeepInspect supports all GenICam-compliant USB 3.0 and GigE cameras, giving you the flexibility to work with the hardware you already have on your production line. Fully tested and compatible brands include Basler, IDS, Baumer, Omron Sentech, Allied Vision, FLIR, HIK Robot, and Lucid Vision. We also support Area Scan, Line Scan, and Thermal cameras, covering a wide range of inspection environments and product types.
DeepInspect is built specifically for defects that are random and unpredictable in nature, such as cracks, scratches, surface anomalies, missing components, seal failures, and label errors. Unlike rule-based systems that rely on a defect appearing at a fixed location or in a fixed pattern, DeepInspect uses AI models trained on your actual production data to recognize defects regardless of where they appear or how they look. This is exactly where AI inspection becomes critical: when a crack can appear anywhere on a part, or a scratch has no consistent shape or size, traditional vision systems fail. DeepInspect is trained to catch what others miss. The system has been successfully deployed across over 1,000 unique SKUs in automotive, pharma, electronics, and FMCG industries.
Curious to Learn More?
Download the full use case below!