Every machine vision system Optomech installs has a story — a production problem solved, an audit passed, a batch recall avoided. This is where we publish them.
BIS — Bottle Inspection System
A Silvassa HDPE manufacturer with 4 production lines — 8,000–10,000 bph each — was losing ₹28.4L per year to customer returns and NCRs. BIS deployed. Problem solved.
Read Full Case Study →CIS — Cap Inspection System
An FDA CAPA finding threatened 34% of revenue for this Baddi cap manufacturer. CIS installed on 3 lines at 22,000 cph — CAPA closed 15 days ahead of deadline, supplier status upgraded.
Read Full Case Study →LIS — Label Inspection System
A Hyderabad oral liquid plant had 2 near-miss mislabelling incidents in 16 months. LIS deployed on 4 lines — 6 wrong-label reel loads caught in Year 1. WHO-GMP renewal with best-practice citation.
Read Full Case Study →ISIVS — Induction Seal Verification
A Mumbai nutraceutical company was haemorrhaging brand equity through e-commerce seal complaints. Thermal imaging ISIVS deployed — 94% complaint drop in the first quarter, ₹14L returns cut by >90%.
Read Full Case Study →FOSIS — Flip-Off Seal Inspection
An Ahmedabad parenteral manufacturer had an FDA observation blocking their ANDA. FOSIS installed at 600 seals/min with full 21 CFR Part 11 audit trail — observation closed, ANDA approved.
Read Full Case Study →Statistical analysis of why AQL sampling fails for modern packaging lines — and the real defect-per-million rates quality managers should be planning around.
Coming SoonWhat validation actually means for a vision inspection system, what documents you need, and why a vendor who can provide these saves you months of compliance work.
Coming SoonUnder-heated seals look perfect under visible light. Here's the physics of why only thermal imaging reliably detects partial foil adhesion — and what that means for your quality system.
Coming SoonOptomech Vision reaches a milestone in its installed base, with systems now running in 13+ countries across pharma, FMCG, nutraceuticals, and agrochemicals. [Publish when confirmed]
Coming SoonVisit the Optomech stall for live demonstrations of BIS, CIS, LIS and ISIVS — including AI defect detection and 21 CFR Part 11 compliance workflows for pharma. [Update with booth details]
Coming SoonAnswers to the questions quality managers, plant heads, and compliance teams ask most when researching machine vision inspection for their lines.
Ask Us Directly →Verified results include: ₹28.4L in annual bottle returns eliminated (FMCG, Silvassa); FDA CAPA closed in 75 days with zero defective caps at customer in 10 months (Pharma, Baddi); zero mislabelling in 18 months with WHO-GMP best-practice citation (Pharma, Hyderabad); 99.97% seal integrity and 94% reduction in consumer complaints (Nutraceuticals, Mumbai); FDA ANDA approved and ₹18 crore US market revenue unlocked (Injectables, Ahmedabad).
Commissioning timelines are short. BIS across 4 production lines took 6 days. CIS on each line took under 8 hours with no lost production shift. FOSIS product changeover takes under 15 minutes. Optomech's average commissioning time across its installed base is 6 days.
Yes. Pharmaceutical-spec Optomech systems include 21 CFR Part 11 compliant audit trails, electronic signatures, 3-level access control, and IQ/OQ/PQ validation packages. Documented outcomes include FDA CAPA closure (Baddi), FDA ANDA approval (Ahmedabad), WHO-GMP renewal with best-practice labelling citation (Hyderabad), and Schedule M and EU GMP compliance at multiple sites.
ROI timelines vary but are typically short. One bottle manufacturer recovered investment in under 6 months after eliminating ₹28.4L in annual NCR costs. A nutraceutical company cut ₹14L in annual seal returns by over 90% in Year 1. A parenteral manufacturer unlocked ₹18 crore in US market revenue by achieving FDA compliance. Beyond cost savings, customers report eliminated batch destructions, removed regulatory findings, and improved customer qualification status.
The BIS detects: short moulding, thin walls, flashes, ovality, seal surface damage, choked necks, black spots, burn marks, holes, pinholes, material inclusions, and bottom defects. The AI model is trained on customer parts including normal surface variation, achieving >99.5% detection rate and <0.3% false rejects in commissioning validation.
The ISIVS uses a cooled infrared thermal camera to detect the heat signature of every seal within seconds of leaving the sealing tunnel. Under-heated seals show reduced thermal intensity. Over-heated seals show elevated gradients. Cut and missing liners show a characteristic absence of thermal signal. Detection is 100% non-destructive at full line speed — no pull-tests, no production slowdown.
Yes. Optomech's LIS includes wrong-label detection via reference image matching from a stored SKU recipe library. At changeover, the operator selects the new product recipe. If a wrong-SKU label appears, the bottle is rejected and a supervisor alert fires — with a line hold until acknowledged. In one installation, 6 changeover loading errors were detected in Year 1 before any defective bottles reached packing.
No. Optomech systems automatically divert rejected items without stopping the line. Rejected bottles are diverted by a pneumatic gate. Rejected caps are ejected by an air-blast mechanism before reaching the crimping station. The system logs a high-resolution image and defect classification for every rejected item — providing a complete auditable record without interrupting production.
If you're an Optomech customer who'd like to share results as a case study — named or anonymised — contact us at info@optomech.in or call Chinthaya at +91-9032364140. We document results with your permission and can publish in whichever format you prefer.
Share your packaging format, line speed, and quality challenge. Optomech's engineering team will propose the right system — in days, not weeks.