The Optomech Bottle Inspection System (BIS) performs 100% inline visual inspection of
empty HDPE, PET & PP containers — detecting 40+ defect types across 6 zones at up to
10,000 bottles per hour. Zero slowdown. Zero compromise.
⚡ 10,000 bph🔍 6 Inspection Zones✅ 21 CFR Part 11🏭 200+ Installed📦 5 ml – 5 L Formats
100%
Inline Inspection No Sampling
6
Inspection Zones Per Bottle
10,000
Bottles/Hour Max Throughput
<0.3%
False Rejection Rate
200+
Systems Installed
Optomech BIS installed inline on a pharma bottle line · Silvassa · 3,200+ defects caught/month
Why 100% Inspection
Sampling misses the defects that hurt you most
A 1-in-20 AQL check passes defective batches 95% of the time. One customer complaint,
one regulatory non-conformance, or one market withdrawal can cost more than an entire inspection
system. The Optomech BIS makes 100% inline inspection accessible at FMCG line speeds.
₹
Eliminate customer return costs
One FMCG bottle maker eliminated ₹28.4 lakh per year in customer returns within the first year of BIS installation.
🛡️
Pass regulatory audits with evidence
21 CFR Part 11, GMP Annex 11 and WHO-GMP inspection records are automatically generated, time-stamped and tamper-proof.
⚙️
Catch mould defects at source
BIS identifies which blow-mould cavity is producing defective bottles, enabling targeted maintenance before a full batch is affected.
📊
Drive continuous improvement
Defect trend dashboards and Pareto charts transform inspection data into actionable quality intelligence for your QA team.
Product Family
Four variants. One standard: zero defects.
Every BIS variant is built on the same proven inspection engine. Choose the configuration
that matches your line speed, bottle format and compliance requirements.
⭐ Flagship
🏆
BIS-XL
Maximum throughput, maximum zones, full pharmaceutical compliance. The workhorse of high-volume bottle lines.
Up to 10,000 bph
6 inspection zones
8–12 cameras
21 CFR Part 11 / GMP Annex 11
Bottle sizes: 30 ml – 5 L
HDPE · PET · PP · LDPE
Full SFT / audit trail / e-signatures
🔬
BIS STD+
Full 6-zone inspection for mid-speed pharma, nutraceutical and FMCG lines with compliance reporting.
Up to 8,000 bph
6 inspection zones
6–8 cameras
WHO-GMP / GAMP 5 ready
Bottle sizes: 15 ml – 2 L
HDPE · PET · PP
Batch reports + trend charts
💊
BIS-EDB
Specialist variant for eye-dropper and small-neck bottles — detects defects invisible to the naked eye.
Up to 6,000 bph
Neck-finish + inside + base
High-mag optics
5 ml – 30 ml formats
HDPE · PET · PP
FDA ophthalmic requirements
Compact footprint
🚀
BIS-Basic
Entry-level inline inspection for filled-bottle lines and converters needing a fast start without the full spec.
Up to 6,000 bph
Sidewall + base zones
4 cameras
50 ml – 2 L formats
HDPE · PET · PP
Simple touchscreen UI
Upgradeable to BIS STD+
Standard Across All Variants
What every BIS delivers
Built on 15+ years of machine vision experience in pharma and FMCG — these capabilities
are non-negotiable on every Optomech BIS.
👁️
Industrial Vision Engine
High-resolution industrial cameras with custom telecentric optics, strobed LED illumination per zone, and real-time image processing at full line speed.
🎯
Precision Rejection
Air-blast rejection with PLC-synchronised timing. Defective bottles are ejected with <0.3% false rejects — good bottles are never wasted.
📱
Touchscreen HMI
Intuitive 15" industrial touchscreen with live video feeds, defect classification overlays, and one-touch recipe selection for different bottle formats.
🔄
Fast Format Changeover
Recipe-based changeover in under 2 minutes. Store unlimited bottle recipes including sizes, shapes, materials, and defect sensitivity settings.
📊
Real-Time Analytics
Live defect trend graphs, shift production summaries, Pareto charts by defect type, and mould cavity tracking — all on the machine HMI.
🔌
PLC / Line Integration
Digital I/O for reject signals, alarm outputs, and line-stop triggers. Optional OPC-UA for MES/SCADA integration and centralised QA data.
Average 6 working days from installation to production sign-off — mechanical integration, calibration, recipe creation, operator training, FAT & SAT.
🔧
Remote Support
Secure remote access for diagnostics, recipe updates, and software upgrades. On-site response via Chinthaya and the Optomech service team.
Defect Detection
6 zones. 40+ defect types. Nothing passes.
The Optomech BIS inspects each bottle through six dedicated zones, each with purpose-built
illumination and optics. Every zone's defect sensitivity is independently tunable per recipe.
Base — Spot Defect
Base — Thin Wall
Base — Pin Hole
Inside — Extra Material
Sidewall — Spot Defect
Sidewall — Surface Check
Zone
Defects Detected
Optomech Image
🔲 Sidewall
ScratchesBlack marksDentsDeformationContaminationColour variationWeld linesSink marks
4–6 wrap-around cameras
⬛ Base
Spot defectsThin wallPin holesUnfilled areasSink marksNon-uniform thicknessGate mark issues
Not flatContaminationSurface damageUnevennessFinish defects
Macro top-view optics
🔺 Shoulder
DistortionContaminationSurface defectsWeld marks
Angled side cameras
🔭 Inside
Extra materialContaminationDark patchesForeign particlesInterior streaks
Coaxial inside-view camera
Inside Inspection View
Coaxial Inside Camera
Sealing Surface Inspection
How It Works
From conveyor to quality release — in milliseconds
The BIS operates as an invisible quality gate at full line speed. Bottles enter, are inspected
across all zones simultaneously, and are accepted or rejected — all before the next bottle arrives.
1
Bottle Feeding
Bottles enter the inspection tunnel on the production conveyor — no operator intervention.
2
Zone-by-Zone Imaging
Strobed LED illumination fires per zone. Each camera captures a high-res image in <1 ms.
3
AI-Powered Analysis
Vision algorithms process every image in real time — comparing against trained defect models.
4
Pass / Reject Decision
A PLC-synchronised air-blast rejects defective bottles into a dedicated reject chute.
5
Data Logging
Defect images, timestamps and counts are stored — building your real-time quality record.
Bottle feeding — inline on existing conveyor, no line redesign
Inside the inspection tunnel — multi-zone simultaneous imaging
Software & Compliance
Inspection data your QA team can rely on in any audit
The BIS software platform is purpose-built for regulated environments — from WHO-GMP pharma
facilities to FDA-scrutinised export lines. Every inspection event is logged, every batch
is reportable, and every user action is traceable.
21 CFR Part 11GMP Annex 11GAMP 5WHO-GMPISO 9001IQ / OQ / PQ
✔Tamper-proof audit trail — every inspection event, recipe change, and user login is automatically logged with timestamp and user ID.
✔Electronic signatures — batch release, recipe approval, and report sign-off with 21 CFR Part 11 compliant e-signatures.
✔Role-based access control — operator, supervisor, and admin roles with separate permissions and login credentials.
✔Exportable batch reports — PDF and CSV exports for every batch, SKU, and shift. CAPA-ready defect evidence with captured images.
✔Real-time defect dashboards — live trend charts, shift comparisons, and mould cavity tracking on the 15" touchscreen HMI.
BIS-XL 15" touchscreen HMI — real-time inspection dashboard with live camera feeds, defect classification and batch reporting
Industries Served
Trusted across pharma, FMCG and beyond
The Optomech BIS is installed and running in some of India's most demanding quality-critical manufacturing facilities.
💊
Pharmaceuticals
Tablet, capsule and syrup bottles for domestic and export markets. Full 21 CFR Part 11 and WHO-GMP documentation. CAPA evidence on demand.
👁️
Ophthalmic / Eye-Drop
Specialist BIS-EDB variant for small-neck eye-dropper containers. Detects internal contamination and sealing surface defects at ophthalmic-grade sensitivity.
🧴
FMCG & Personal Care
High-speed inspection at up to 10,000 bph for shampoo, lotion, oil and household chemical bottles. Eliminates customer return costs.
🌿
Nutraceuticals
Protein, vitamin and supplement containers. Seal integrity inspection to prevent moisture ingress and product spoilage.
🧪
Agrochemicals
HDPE containers for pesticides and fertilisers. Detects thin-wall and pin-hole defects that can cause leakage in the supply chain.
🏭
Blow Moulding Converters
Inline inspection at the moulding machine output. Cavity-level defect tracking identifies bad moulds before a full production run is affected.
Every figure below comes from a documented customer case study — not a brochure estimate.
₹28.4L
Annual returns eliminated
An FMCG bottle maker in Silvassa eliminated ₹28.4 lakh per year in customer return claims within 12 months of BIS installation. 3,200+ defective bottles caught per month.
Verified detection rate across all 6 inspection zones at full production speed. Customer returned-goods complaints dropped to zero within 90 days of go-live.
From delivery to production sign-off in an average of 6 working days — mechanical fit, camera calibration, recipe creation, operator training, and FAT/SAT documentation.
A pharma injectable manufacturer in Ahmedabad secured FDA ANDA approval and unlocked ₹18 crore in US export revenue after installing the Optomech FOSIS — same vision platform as BIS.
Everything you need to know about the Optomech BIS
Answers to the questions most asked by quality managers, production engineers and procurement
teams — before and after purchase.
The Optomech BIS detects 40+ defect types across 6 zones: sidewall (scratches, black marks, dents, deformations, contamination, colour variation), base (spot defects, thin wall, pin holes, unfilled areas, sink marks), neck-finish (chipped neck, thread damage, short shot, warpage, flash), sealing surface (flat, contamination, damage, unevenness), shoulder (distortion, surface defects), and inside (extra material, contamination, dark patches, foreign particles).
The Optomech BIS-XL inspects up to 10,000 bottles per hour inline with zero production slowdown. Standard and EDB variants are configured for 6,000–8,000 bph depending on bottle format and zone configuration.
The BIS inspects HDPE, PET, PP, and LDPE containers — including tablet containers, syrup bottles, eye-drop bottles, ampoule-style containers, FMCG bottles, and cosmetic packaging — in sizes from 5 ml to 5 litres.
Yes. The BIS-XL and BIS STD+ include a 21 CFR Part 11 compliant software module with full audit trail, electronic signatures, role-based access control, and tamper-proof batch reports. The system also meets GMP Annex 11, GAMP 5, and WHO-GMP requirements.
Average commissioning time is 6 working days, including mechanical integration, camera calibration, recipe creation for each bottle format, operator training, and FAT/SAT sign-off documentation.
Yes. The BIS mounts inline on the blow-moulding output conveyor or at any pre-filling stage. It uses a standard reject-air-blast mechanism and communicates with line PLCs via digital I/O or OPC-UA. No line redesign is required in most installations.
The BIS achieves a false rejection rate of less than 0.3%, meaning good bottles are almost never wasted. Detection sensitivity and rejection thresholds are tunable per defect type per recipe.
The BIS-XL uses 8–12 high-resolution industrial cameras depending on bottle format and defect specification — typically 4–6 sidewall cameras plus dedicated base, neck-finish, sealing surface and inside cameras.
The BIS produces real-time defect trend dashboards, shift/batch/SKU-wise reports, defect classification histograms, rejection logs with captured images, and exportable PDF or CSV audit reports. All data is stored with a tamper-proof audit trail in 21 CFR Part 11 mode.
Customers typically recover the investment in 12–18 months through: eliminating customer returns (one FMCG customer eliminated ₹28.4 lakh/year), avoiding regulatory non-compliance costs, and reducing manual inspection labour. The system also enables CAPA closure with documented evidence for QMS and regulatory audits.
Get in Touch
See the BIS running on your bottle, at your speed.
Request a live demo with your actual bottle formats. Our engineers will show you exactly
which defects the BIS catches — and exactly what your ROI looks like.
