Hunan Zhengzhong Pharmaceutical Machinery Co., Ltd.
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Visual Inspection Machines
  • Automatic Vial Freeze-Dried Powder & Residual Oxygen Inspection Machine
  • Automatic Vial Freeze-Dried Powder & Residual Oxygen Inspection Machine
  • Automatic Vial Freeze-Dried Powder & Residual Oxygen Inspection Machine
  • Automatic Vial Freeze-Dried Powder & Residual Oxygen Inspection Machine
Automatic Vial Freeze-Dried Powder & Residual Oxygen Inspection Machine
Highlights
  • Combines visual inspection and laser spectroscopy for dual-function performance
  • Achieves inspection speeds of up to 400 vials/min
  • Fully servo-driven, multi-station system with HMI user interface and audit trail for compliance and traceability
  • Built with world-renowned components including Basler cameras (Germany) and Mitsubishi PLC & servo motors
  • Ensures precision inspection of both visual defects and residual oxygen level

JLYWD Automatic Visual Inspection (AVI)

Automatic Vial Freeze-Dried Powder & Residual Oxygen Inspection Machine

Pharma visual inspection equipment for detecting various defects of vials containing lyophilized products ranging from 2ml to 30ml at speeds up to 400 pcs/min
Technical Specifications
  • Speed: 400pcs/min (max.)
  • Applicable container: 2-30ml vials filled with freeze-dried powder (lyophilized powder)
  • Power supply: 8kW, 380(1±5%)V, 3 phase AC, 50Hz
  • Worktable height: 900mm
  • Machine dimensions (L×W×H): 2900×1830×2020mm
  • Machine weight: approx. 2600kg
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Applications

This inspection machine is purpose-built for inspecting freeze-dried powder (lyophilized) vials, whether made from molded or tubular glass. It performs automated detection of:

  • Surface particles and visible contaminants
  • Appearance defects such as cracks, chips, or deformations
  • Filling accuracy (powder volume)
  • Gas seal integrity using residual oxygen analysis

Typical inspection points include the vial bottom, cap area, powder cake, and outer surface, ensuring your product meets both visual and functional safety standards.

Applications
  • Bottom defects
    Bottom defects
  • Foreign particles in the powder
    Foreign particles in the powder
  • Surface foreign particles
    Surface foreign particles
  • Bottom defect
    Bottom defect
  • Cap defects
    Cap defects
Features

Engineered as an all-in-one inspection solution, this pharmaceutical inspection machine combines visual inspection for visible defects and laser spectral analysis for residual oxygen detection, offering unmatched accuracy, flexibility, and compliance for freeze-dried vial production.

  • Dual-function technology: Integrates computer vision and laser spectroscopy to detect both physical and gas-related defects in a single inspection cycle
  • Adjustable high-precision inspection: Equipped with high-resolution industrial cameras, the system delivers greater accuracy than manual inspection, with customizable detection thresholds based on your quality standards
  • Full-servo control system: Compact structure and stable transmission reduce the risk of vial breakage during operation
  • Flexible format changes: Pin-and-hole design for all size parts and a lifting turntable make format switching quick and hassle-free
  • Complete traceability: Multi-level user permissions, customizable access, and full audit trails ensure your operation stays compliant with GMP and regulatory requirements

Whether you're scaling up production or strengthening quality assurance, this inspection machine gives you the control, speed, and reliability you need for freeze-dried vial inspection.

Standard Inspections

This system conducts three critical inspection functions across multiple dedicated stations:

  • Surface impurity detection: Identifies particles on the vial surface or within the powder cake
  • Appearance defect inspection: Detects flaws such as cracks, chips, or cap defects
  • Gas seal integrity check: Measures residual oxygen to confirm airtight sealing

Each inspection type is assigned to one or more workstations, ensuring precise evaluation of all relevant areas across the vial body. This structure supports high-speed, consistent, and comprehensive inspection across every production batch.
The specific inspection tasks assigned to each station, as well as the corresponding inspection areas on the container body, are shown in Figure.

Standard Inspections
Working Process

The products convoyed by belt, then transmitted from worm wheel for separation to infeed star-wheel, inspection turnplate, outfeed transmission star-wheel etc. for online inspection at inspection stations. The products will be transmitted separately to the corresponding tray by outfeed star-wheel control according to the real-time inspection results.
There are 7 inspection stations in total a tinfeed star-wheel, inspection turnplate and outfeed transmission star-wheel. The overall process flow and stations distribution of the equipment shown as figure:

Working Process
Working Principle

This inspection system operates in two integrated stages to verify both visual integrity and residual oxygen levels in freeze-dried vials:

  • Visual inspection for freeze-dried powders:

    Using machine vision, each vial is rotated smoothly on the turntable while high-speed industrial cameras capture multiple images from different angles. These images are processed by a distributed computing system, which analyzes them for visible impurities or appearance defects. Based on the analysis, the system automatically separates qualified and defective vials.

  • Residual oxygen detection:

    This function relies on laser spectral analysis. As the vial passes through the inspection zone, a semiconductor laser emits a beam at a wavelength precisely aligned with oxygen’s absorption spectrum. A sensor on the opposite side measures oxygen levels by detecting absorption patterns. If the residual oxygen exceeds the preset threshold, the system flags the vial as non-compliant and removes it from the production line.

By combining these two advanced techniques in a single compact system, you gain precise, efficient, and fully automated inspection without compromising production speed or product safety.

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Can your visual inspection machine handle different vial sizes and what defects can it detect?

Yes, our visual inspection machine is compatible with freeze-dried vials ranging from 2ml to 30ml. It inspects for:

  • Surface impurities
  • Appearance defects
  • Powder volume accuracy
  • Residual oxygen levels to confirm seal integrity

Why is automated visual inspection (AVI) so important in pharmaceutical manufacturing?

AVI plays a critical role in ensuring product safety for injectables and lyophilized drugs, which are often administered directly into the body. By detecting foreign particulate matter (FPM) like glass or fibers, the system helps maintain product sterility and effectiveness. Missed defects could lead to costly recalls or regulatory action. With AVI, you minimize risk and ensure every unit meets global standards.

How does automated inspection compare with manual visual checks?

Unlike manual inspection, which can be subjective and fatigue-prone, automated systems:

  • Deliver consistent and repeatable results
  • Support high-speed, 24/7 production
  • Store detailed inspection records, including images and defect metrics
  • Easily adapt to new product formats

In short, AVI improves accuracy, reliability, and traceability while reducing labor strain and the risk of human error.

Interested in learning more about our Visual Inspection and Leak Testing Equipment

Get in touch with us today!
Inspection Equipment
Visual Inspection Machines
Visual Inspection Machines
Leak Testing Machines
Leak Testing Machines
Visual Inspection & Leak Testing Machine
Visual Inspection & Leak Testing Machine
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Products
  • Visual Inspection Machines
  • Leak Testing Machines
  • Visual Inspection & Leak Testing Machine
Test Methods
  • Visual Image Processing
  • Vacuum Decay
  • High Voltage Leak Detection (HVLD)
Applications
  • Liquid Dosage
  • Freeze-Dried Powder
Contact Us
zzoneinspection@gmail.com
+86-731-88906436
+86-18692213322 (Sabrina Wang)
+86-13786180170 (Cici Li)