Integrated security inspection for pharmaceutical labels

The Control Group, a New Jersey-based pharmaceutical manufacturer of flexographic labels and flexible packaging, has complemented over 30-years of manufacturing expertise with Advanced Machine Vision Technology from Rotoflex International. As an international supplier of eFinishing and inspection solutions, Rotoflex offers basic to complex accurate security inspection systems.

The Control Group recently installed a 28", 8-color Aquaflex FPC servo press, complemented by a Rotoflex VLI-700 eDrive inspection rewinder

The company has moved into a 60,000 square foot facility to house its flexible packaging operation. The Control Group has three divisions and 10 presses. Major product categories include flexible packaging films, labels, and package inserts for pharmaceutical, health care, cosmetic, and consumer packaging applications.

‘Developing a quality inspection process to guarantee accurate and secure labeling for our pharmaceutical clients has been an integral part of our success. Our goal was to implement an initiative that would push quality control to the highest level possible, based on the most advanced procedures and technology available today,’ said Jeffrey Levine, partner, the Control Group.

‘We are very impressed with how the Rotoflex vision system meets the strict demands of our SOP processes. The integrity of the label is critically important and the Rotoflex system far exceeds human or strobe inspection capabilities. The bottom line is our partnership with technology leaders such as Rotoflex gives us an exceptionally strong competitive advantage in today's market. We can put out the best product and do it at a very competitive price,’ added Levine.

According to recent studies, world pharmaceutical packaging demand is projected to increase to 6.3 per cent annually to over $30 billion in 2009. The US will remain the largest consumer of pharmaceutical packaging as its advanced drug-producing sector introduces new sophisticated therapies with specialized packaging needs.

‘You just can't survive in this industry with equipment that's 20-years old. If you want to compete with today's high quality assurance standards, you need state-of-the-art equipment, expertise, and technology. If your supplier is stagnant using old technology like strobe lights - you're in trouble,’ said Levine.

Advanced Machine Vision System from Rotoflex International uses a reference based inspection method for quality control. During a ‘Learn’ process, the system stores a known good image and then compares it with each consecutive image using tolerance for color deviation, registration and defect size.

All interaction with the vision system is done via an intuitive Human Machine Interface (HMI). The system identifies the defects on a monitor, so the operator can quickly locate and verify the problem. The vision system provides quality control by identifying various faults including color defects, oil defects, missing print, color changes, register movement between colors, register movement print to die cut, missing labels, matrix, splice and flags.