The Challenge
A Schedule M / pharma oral-solid packer in Telangana runs child-resistant (CR) caps on an oral-solid packaging line. For CR closures, the wad (liner) is a critical quality attribute: a missing, folded, slid, cut, or wrinkled wad can compromise seal integrity and child-resistance performance before the pack reaches the patient.
Manual or sampled checks struggle to keep pace when the line is sized for 400 caps per minute. Wad faults are often subtle from the top face alone — folding, slide, cut edges, and wrinkling typically need a dedicated wad-facing view under consistent lighting, at full line speed.
The plant needed an inline, application-built machine-vision station that could inspect every CR cap for the wad defect set in their QA specification — while keeping the plant identity anonymised for public publish.
The Solution
Optomech supplied the CIS — Cap Inspection System, configured for this CR-cap / wad application at 400 caps per minute. CIS is Optomech’s dedicated cap inspection platform (see also CIS Online for related online configurations).
Inspection recipes were aligned to the wad defect classes specified by the customer’s quality team:
Compared with assembling a general-purpose Cognex- or Keyence-style vision cell in-house, an application-specific CIS from an Indian OEM brings factory-built mechanics, lighting, reject handling, and Hyderabad-based applications support. For buyers comparing platforms, see Cognex / Keyence vs Indian machine-vision OEM. Live demos are available at our Hyderabad machine vision & metrology facility.
The programme covered 8 lines / stations, with commissioning completed in 1 week. IQ/OQ/PQ was completed by Optomech Engineers; all validation documents were prepared and handed over to the customer.
Results & Scope
| Item | Fact (sales-approved) |
|---|---|
| Industry | Pharma — oral-solid packaging (Schedule M framing) |
| Publish region | Telangana (plant city not published) |
| Product | Child-resistant (CR) caps |
| System | Optomech CIS — Cap Inspection System |
| Line speed | 400 caps per minute |
| Defects configured | Wad presence/absence · folding · slide · cut · wrinkled wad |
| Detection rate | 99.9% |
| False reject rate (FRR) | less than 0.5% |
| Number of lines / stations | 8 |
| Commissioning duration | 1 week |
| IQ/OQ/PQ / audit | IQ/OQ/PQ completed by Optomech Engineers; all validation documents prepared and handed over to the customer. |
Defect / system gallery
Illustrative CIS defect types and system imagery from Optomech product assets — not photos from this Telangana plant (customer line imagery withheld under NDA / anonymised publish).
Need wad / CR-cap inspection at line speed?
Share your cap format, wad type, and target cpm. We’ll propose a CIS configuration and demo path — Hyderabad lab or your plant.
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