Combining multiple inspection technologies in one machine

The "perfect" inspection line can always be a balancing act. On one hand, you need to guarantee 100% container integrity and purity; on the other, you are constantly fighting for floor space, trying to minimize complex handovers between machines, avoiding falsely rejected containers resulting in unnecessary waste and pushing for higher throughput.

Separating Automated Visual Inspection (AVI) from Container Closure Integrity Testing (CCIT) is increasingly becoming a bottleneck. Every time a vial moves from one machine to another, the risk of breakage or cosmetic defects increases, and the data trail becomes more fragmented. By consolidating these technologies into a single, integrated platform, we aren’t just saving space; we are creating a more robust, data-driven window into the quality of every single container.

At WILCO, we see the inspection process as a holistic challenge. Depending on your specific product, the ideal setup will vary. Integrating different inspection technologies into one machine minimizes the risk of damaging containerswithout slowing down the line.

Visual Inspection with Headspace Analysis

Combining AVI with Laser-based Headspace Analysis is perhaps the most effective way to ensure the long-term stability of oxygen-sensitive, oily, toxic or thermally sealed liquid products.

• Quality control of vial closure: While cameras detect physical defects like bent caps or glass chips, HSA confirms the functional seal.
• Leak detection: HSA is used to measure the gas composition, e.g. the O2 concentration, inside the vial to find leaks that a camera simply cannot see.
• Non-destructive leak testing: Because the laser passes through the headspace, 100% of the batch can be tested.
• Measurement of oxygen ingress: Critical for products that degrade in the presence of O2.
• Visual Inspection of 1ml – 100ml vials: A wide range of formats can be handled on a single platform.
• Static optical path: Using a fixed optical path minimizes the mechanical complexity and vibration that can interfere with high-resolution imaging.

Visual Inspection with Near Infrared Spectroscopy and Headspace Analysis

This "triple-combination" is the ultimate setup for complex lyophilized products. It allows for a total assessment: AVI for particles and cake appearance, NIR for residual moisture, and HSA for the measurement of oxygen (O₂), carbon dioxide (CO₂), or the total pressure based on the measurement of water vapor (H₂O).

Headspace Analysis with Near Infrared Spectroscopy

In some specialized applications, the focus is entirely on the internal environment. Pairing HSA and NIR ensures that the cake is dry (NIR) and the seal is tight (HSA), providing a non-destructive alternative to traditional moisture analysis.

The VARIO MTX was developed to handle these multi-technology requirements without the typical compromises in speed or reliability. It is a modular inspection machine designed for the most demanding pharmaceutical environments.

• Robustness through OptiX™: Our static optical path technology ensures that the cameras get a clear, consistent "look" at the product. This stability and elimination of vibrations is what allows for the high detection rates and low false-reject rates that quality managers require.
• Full integration of AVI with HSA and NIRS: We don’t just "mount" different sensors; we integrate them into a single control system. This means one HMI, one batch report, and one validation effort for a comprehensive inspection suite.
• Proven Customization: We understand that every process is unique. We have successfully deployed highly complex configurations for global pharma producers.
• High-Speed Performance: The VARIO platform is built for throughput, with configurations supporting 300, 400, and up to 500 containers per minute.
• Traceability: Integrated code readers ensure that every inspection result is tied to the specific container, supporting your Track & Trace requirements.

VARIO MTX is ideal for:

• 100% inspection of vials with lyophilizates: Managing the specific challenges of moisture and vacuum.
• Ampoules: Rapid leak and particle detection.
• Glass & plastic containers: Flexible handling for different materials.
• Total Product Range: Optimized for liquid, lyophilized, and solid products.

By bringing these technologies together, the VARIO MTX doesn’t just inspect; it provides a comprehensive quality assurance shield for your most critical products.