Application

Inspect Pharmaceutical Vials

AI-powered vial inspection detects cracks, particles, fill-level anomalies, and contamination at production speed — ensuring GMP compliance.

Free POC on Your Vials See pricing

Logi205 dimensional control screen for 5 ml clear vials: neck and finish measurements per cavity, trend charts and counters for good and rejected vials

The Challenge

Pharmaceutical vial inspection by eye is slow, unreliable, and risky. Missed defects can reach patients, triggering recalls, regulatory action, and liability.

01
Manual inspection is unreliable
Human inspectors miss micro-cracks, particle contamination, and fill-level drift — especially at high throughput.
02
GMP & regulatory risk
Inspection records must be traceable and auditable. Manual processes lack consistency and documentation.
03
Sampling AQL insufficient
AQL sampling of pharma vials misses critical defects. 100% inline inspection is the industry standard.
04
Recall & liability exposure
A single defective vial reaching the patient triggers recalls, regulatory fines, and reputation damage.

Glass vial seen from above with a particle of debris detected at 0.86 confidence — Debris 0.86

How AI Vial Inspection Works

100% GMP-compliant inspection

Multi-angle imaging — captures vial from all angles (cracks, seams, bottom)

Detects micro-defects — cracks >50µm, particles >10µm, fill-level drift ±2%

Full traceability — every vial logged with images and results for audit trail

Production speed — processes 1,000+ vials/hour without line interruption

Inspection on a Real Line: Two Logi205 Screens

Dimensional control of vials

Two cameras measure the neck and finish of every vial in millimetres, and a third checks the mouth from above. The screen shows the result per mould cavity, how each measurement trends over time, and the count of good and rejected vials. Shown here: a 5 ml clear vial.

Cosmetic control of vials

Cameras capture the body, shoulder, neck, bottom and top of every vial. Rejects are counted per zone and the latest rejected images stay on screen, so the operator sees straight away where a cosmetic defect starts. Shown here: a 2 ml amber vial.

Logi205 cosmetic control screen for 2 ml amber vials: body, shoulder, neck, bottom and top images, rejects per zone and the latest rejected images — Logi205 · cosmetic control

Expected Results

Detection accuracy: >99.8%; Detection accuracy
Monthly savings (typical): €8-15k; Monthly savings (typical)
GMP compliance: 100%; GMP compliance

Real-World Example

Pharma Packaging Company (Europe)

“We were manually inspecting ~50k vials/week with a team of 8. We caught maybe 85% of defects. AI now runs 100% inspection with 2 operators watching alerts. We’ve cut escaped defects by 95%.”

Quality Manager, 500k+ vials/month

Free feasibility test

See AI Inspection on Your Vials

Send us 30 vial samples (good + defective) or high-resolution photos. We’ll test detection accuracy and show you the full audit trail.

parts or photos: 20; parts or photos
days to results: 5-7; days to results
no commitment: €0; no commitment

Results before contract Book your free test See pricing +39 049 825 6850

FAQ

Frequently Asked Questions

Another question? Call us on +39 049 825 6850 or email info@logirobotix.com.

Is AI inspection FDA/EMA compliant?

Yes. The system generates full audit trails, image documentation, and inspection records suitable for FDA, EMA, and GMP audits. We recommend having your regulatory team review the process during the POC.

What types of defects can it detect?

Cracks, micro-fractures, seam defects, particle contamination, fill-level drift, colour anomalies, label defects, and cap defects. We can customize detection for your specific defect types.

Can it handle different vial types/sizes?

Yes. The AI trains on your specific vial type (Type I, Type II, Type III glass; clear, amber, etc.). If you produce multiple vial SKUs, we can set up multi-model detection or train a unified model.

What about integration with existing equipment?

The system integrates with most filling/capping lines. We can connect to your line PLC/MES for real-time rejection and logging. No modifications to the line itself are required.

How much does it cost?

Quality Control plan starts at €1,800/month (multi-camera setup). For complex pharma inspection, we often recommend custom pricing. Savings typically reach €8-15k/month in reduced defect escapes and rework.

Trusted on production lines at