Visual Package Inspection

Visual Package Inspection

Visual package inspection is an important part of the manufacturing process.  This visual inspection can either be done by hand or via automated process.  The method chosen depends upon the quantity of product being manufactured and the machinery available. Also, it's important to consider if there are standards in which you will be evaluating the seal surface against such as the ASTM 1886. Obviously, the importance of exacting visual inspection for a bag of surgical blades will be different than a bag of pretzels. The value of visual inspections on sterile pouches is becoming more valuable as it offers a non-destructive in-process methodology that can quickly be performed by front-line employees such as packaging machine operators. It's important to understand the difference between visual inspection of the various film substrates as they all present differently under the visual inspection process.

Manual Inspection

Visual package inspection can be done by hand.  This process relies on human inspection to ensure visual integrity of the outgoing product.  Traditionally, most inspections have been done manually.  People can easily recognize specific defect types, color variation, and size discrepancies.  This brings a high degree of accuracy to the inspection process.

As different concerns or problems arise in the manufacturing process, human inspector can be informed of these specific concerns and easily trained to detect these deficiencies.  Some larger manufacturers will have manual visual inspection on just a sample from each batch of products.  This is more time advantageous, but may not detect all the defective products.

Under the new sterile barrier system, seal integrity from heat seals must be evaluated. A common way to evaluate integrity is through visual seal inspection. Because of some possible discrepancies in visual inspection methodology, a standard was developed to unify and ultimately codify a process in which to visually inspect a pouch. Our firm has actually created a patented device for the sole purpose of evaluating possible seal breaches and failures through visual inspection. Our Viu box exaggerates the seal topography through side-lighting. This increases visual acuity to the inspector and makes visual inspection a great non-destructive test methodology.

Now that there is a standardized device and an ASTM standard, visual inspection can create a linear methodology that should have repeated results irrespective to the person performing the visual inspection. Although visual inspection is not meant to be the last word in seal integrity, it is certainly a cost-effective system that can be performed often. It is in the regular testing that makes the visual inspection so valuable to packagers of nearly any product but certainly visual inspection for medical device packaging that the value is irrefutable. Although visual inspection is obviously not meant for companies producing tens of thousands of sealed bags or pouches, it however is very useful for companies that are producing less than 5000 pieces a day and will only randomly visually inspect. For companies with this throughput, the expensive cost of an automated visual system would certainly be prohibitive.

Automated Inspection

With recent technology improvements, visual package inspection can be performed by machines.  These machines are designed with a photo eye that can detect flaws in the products as they pass under it.  They can be programmed to detect weight differences, mismarked package labels, and other inconsistencies.  The amount of products that can be inspected in a given time is significantly higher than what can be done manually.

The inspection will always be consistent; machines do not suffer from fatigue.  It also takes the subjectivity out of the inspection process.  These machines can also be linked to other machines in various stages of the production process.  The inspection machines can often notify the operator of the machine that is responsible for the defects, having the problem fixed right away.  This cuts down on waste caused by improperly functioning production machines.

The cost of purchasing these automated inspection machines may be too great for smaller manufacturing operations.  Also, the machines are only as effective as they are programmed to be.  While they are able to detect some types of defects, others may go undetected.  A human inspector is more able to adjust to changing defects.

Proper inspection decreases the amount of defective products that leave the manufacturing plants.  It is also important for consumers to perform visual package inspection when making a purchase.  Whether on the manufacturing end or the consumer end, visual package inspection is an important factor in ensuring the integrity of the product.

Visual Package Inspection