Vials and ampoules are transparent, which ought to make inspection easier but does the opposite: glass fragments in a clear liquid and glare on the meniscus often leave conventional vision with nowhere to start.
Vials and ampoules are the most common containers for injectables, and after fill-finish three things must be confirmed at once: whether the fill level sits within the specified range, whether the seal (stopper or fusion seal) is intact, and whether clear particles or glass fragments have entered the container. A failure in any one bears directly on patient safety.
The challenge is the transparent system itself: the liquid is clear, glass fragments and wall refractions easily confuse vision; micro-cracks at an ampoule fusion-seal tip and a slightly lifted vial stopper are subtle and hard to discern; and the high-speed fill-finish line leaves a very short window per unit. Meanwhile, defects like glass fragments and fusion micro-cracks are exceptionally scarce on a very high-yield line.
One High-Speed Pass, Three Checks at Once
The DaoAI AI-AOI high-speed inspection solution captures once at the post-fill-finish station and judges in parallel: deep learning checks whether the fill level is within tolerance, inspects the integrity of the stopper or fusion seal, and performs high-sensitivity detection specifically for glass fragments and particles in clear liquid. For rare defects such as glass fragments and fusion micro-cracks, APDT few-shot learning models and deploys quickly, with an auditable data trail aligned to GMP.
- Fill level, seal, and clear particles/glass fragments detected together in one capture
- Deep learning cracks the refraction and glare of transparent systems
- APDT few-shot for rare defects like glass fragments and fusion micro-cracks
- High-speed inspection without slowing the beat, GMP-auditable and traceable throughout
Transparent never means simple: only by taking on refraction, glare, and rare defects together do you truly guard the last gate of injectables.
After go-live, the plant achieved three-in-one in-line full inspection of fill level, seal, and glass fragments for vials and ampoules, markedly strengthened clear-particle and glass-fragment detection, drove seal-defect and fill-deviation escapes toward zero, ran stably at high-speed cadence, and passed GMP validation audits completely.