Inline Cap Inspection with Liner — 100% at 22,000 Caps/Hr

The CIS Online is a single-camera, inline machine vision inspection system designed specifically for pharmaceutical closures with liners. It is placed directly on the customer's conveyor — typically after the liner insertion machine — and inspects 100% of caps at up to 22,000 per hour. It detects both cap defects (flash, short moulding, breakage, ovality) and liner defects (no liner, double liner, misalignment, foil folding, damaged liner).

The CIS Online is placed inline on the customer's existing conveyor, typically after the closure assembly machine and automatic liner insertion machine — the point where the inner cap and outer cap have been assembled and a liner has been inserted. At this position, 100% of caps are verified before they travel to the capping or bottling machine. No new conveyor or feed system is required — the CIS Online integrates into your existing line layout.

The CIS Online detects six liner defect types: No liner (missing liner) — the most critical, meaning the cap has no liner at all; Double liner — two liners in one cap, with optional laser confirmation for greater certainty; Liner misalignment — liner placed off-centre or tilted; Damaged liner without silver foil — aluminium layer missing; Half moon liner damage — partial defect in the liner; and Foil folding — the liner foil folded over itself during insertion. Each of these would result in an induction sealing failure if the cap were applied to a filled bottle.

The CIS Online is a single-camera inline system specifically designed for pharmaceutical caps with liners on bottling lines — it specialises in liner integrity and cap quality at 22,000 caps per hour, fitting directly onto your existing conveyor. The CIS-XL is a standalone four-camera system providing full 360-degree surface inspection (top, bottom, inside, sides) at 14,000 caps per hour with AI-powered defect classification and direct integration with injection moulding machines — suited for cap manufacturers inspecting caps at the point of manufacture.

Yes. The CIS Online detects double liner defects using its machine vision camera. For maximum certainty in double liner detection — particularly where the two liners are tightly stacked — an optional laser sensor is available. Double liners cause induction sealing failures and can lead to leaky bottles, making this detection important for pharmaceutical quality assurance.

The CIS Online inspects up to 22,000 pharmaceutical caps per hour — making it suitable for high-speed pharmaceutical bottling and packaging lines. All 22,000 caps are inspected individually with 100% coverage — there is no sampling or spot-checking.

The CIS Online provides: real-time display of the last 100 defects on screen; product-wise database storage of all inspection results for complete batch traceability; reports exportable to Excel with defects classified by type per shift; auto-scheduled reports over the network; images of all rejected caps stored for quality audit reference; and 3-level access control (User, Supervisor, Administrator) with separate passwords. These features support GMP documentation requirements, Schedule M compliance, and customer audits.