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.
FAQ
What challenges are faced in the inspection of vials and ampoules?
Inspecting vials and ampoules is challenging. In the transparent system, it's hard to distinguish glass chips from the refracted light of the bottle wall. Micro - cracks in ampoules and slight lifting of vial stoppers are difficult to identify. The inspection time on high-speed lines is short, and defective samples are rare. DaoAI can handle these.
How does the DaoAI AI-AOI high-speed lamp inspection solution address the inspection challenges?
The DaoAI AI-AOI high-speed lamp inspection solution captures an image and makes a judgment synchronously. It uses deep learning to determine the liquid level, inspects seal integrity, and highly sensitively identifies foreign objects. APDT few-shot learning is used for rare defects, and the data meets GMP requirements.
What are the effects after the solution is launched?
After the solution is launched, in - line full inspection of liquid level, sealing, and glass chips for vial and ampoule filling can be achieved. The detection ability of transparent foreign objects is enhanced, the missed inspection of sealing defects and liquid level deviation approaches zero. It operates stably and passes GMP verification and audit.