AI-Powered Visual Inspection for Pharmaceutical Packaging

MedPack IndustriesPharmaceutical Manufacturing4 months

99.7%defect detection accuracy

The Challenge

Pharmaceutical packaging line producing 50,000 units/day with manual quality inspection catching only 92% of defects. Missed defects resulted in costly recalls and regulatory penalties averaging $500K per incident.

Our Solution

Deployed a real-time computer vision system using custom-trained YOLO models on edge devices (NVIDIA Jetson). The system inspects label alignment, seal integrity, print quality, and barcode readability at line speed. Integrated with the production MES for automatic rejection and quality reporting.

Results & Impact

99.7% defect detection accuracy (up from 92%)

Inspection speed: 120 units/minute at full line speed

Zero recall incidents in 8 months since deployment

Annual savings of $2.1M in recall prevention

FDA 21 CFR Part 11 compliant

Technologies Used

🎯YOLO🔥PyTorch💻NVIDIA Jetson👁️OpenCV🐍Python🚀TensorRT📡MQTT🐳Docker

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