A Deep Dive into the Engineering Behind Optomech’s Flip-Off Seal Inspection System

When you hear the term Flip-Off Seal Inspection System, you might just imagine a camera checking caps. But what makes FOSIS stand out is the precision-engineered coordination between its mechanical, optical, and software components — all working in sync to deliver 100% inline inspection at 600 caps per minute.

In this blog, we’ll break down what the FOSIS machine really is, what each part does, and how these components work together to eliminate defective caps from your packaging line.

What is FOSIS – the Flip-Off Seal Inspection System?

FOSIS (Flip-Off Seal Inspection System) is an automated vision inspection machine designed specifically for pharmaceutical flip-off seals. These seals are critical in protecting vial sterility and must be free from:

– Black spots
– Short fills
– Wrinkles
– Missing plastic caps
– Shell damage or crimp defects

FOSIS inspects each cap using high-speed cameras and advanced algorithms, removing defective ones in real time — no sampling, no slowdowns, no human error.

Key Components of the Flip-Off Seal Inspection System (Part-by-Part Breakdown)

1. Vibratory Bowl Feeder

Feeds caps into the system in a uniform orientation and controlled flow. Uses vibration to move caps into the inspection line with proper spacing and alignment. Ensures that each cap is facing the camera correctly for consistent image capture.

2. Inspection Conveyor

Transports caps through the camera station at constant speed. A synchronized conveyor maintains spacing and timing to match the camera frame rate. Ensures smooth flow and avoids motion blur during inspection.

3. High-Speed Vision Cameras

Capture images of each cap from multiple angles (top, side, internal). Industrial-grade cameras take high-resolution images in milliseconds. Without sharp, fast imaging, defects would be missed.

4. Custom Lighting Module

Enhances visibility of surface and internal defects. Uses diffused LED lighting positioned to eliminate shadows and enhance contrast. Ensures accurate defect detection under consistent light.

5. Defect Detection Software (21 CFR Part 11 Compliant)

Analyses captured images in real-time and classifies defects. Advanced algorithms match each cap against a ‘good’ reference profile. It’s the brain of the system — deciding what’s acceptable and what’s not.

6. Defect Rejection Mechanism

Automatically removes defective caps from the production line. Air-jet or mechanical pusher diverts rejected caps into a separate bin. Keeps your line running without manual sorting.

7. Touchscreen HMI (Human-Machine Interface)

Operator control panel for settings, logs, and monitoring. 21″ industrial touchscreen with product library, defect stats, and real-time previews. Essential for fast changeovers and audit traceability.

8. Report Generation & Data Logging System

Tracks inspection data by batch, shift, or time. Automatically exports to Excel or network systems on schedule. Provides the proof for compliance, root cause analysis, and QA documentation.

How These Parts Work Together

Each component in FOSIS is mechanically and digitally synchronized to ensure seamless operation:

1. Caps are aligned and fed →
   2. Conveyed through camera zone →
   3. Illuminated and scanned →
   4. Images analyzed in real-time →
   5. Defective ones rejected immediately →
   6. Reports generated — while the line keeps moving.

Engineering That Scales with Pharma Demands

FOSIS is not just precise — it’s designed for high-throughput, audit-ready production.

Speed: Up to 600 caps per minute
Cap Size Compatibility: Dia 15 mm – 36 mm
Defects Detected: 20+ visual defect types
Compliance: 21 CFR Part 11 Ready
User Control: Multi-level access (U/S/A)
Reports: Excel export + network ready

Conclusion: This Isn’t Just a Machine — It’s a QC Upgrade

If you’re still doing manual cap inspections or random sampling, you’re accepting risk by default. FOSIS gives you control. Accuracy. Speed. And confidence.
Designed, built, and supported by Optomech Engineers, FOSIS is the gold standard in Flip-Off Seal Inspection System for the pharma industry.

📧 Want to see the machine live or request a brochure?
Contact us at: sales@optomech.in
🌐 www.optomech.in/flipoff-inspection-system-2