Zero tolerance for errors
In the pharmaceutical industry, precision is paramount. An incorrectly placed decimal point in dosage instructions, a slight change in batch number or a subtle colour change on a warning label can have serious consequences. Consequences can include production stoppages, batch recalls, regulatory audits, and threats to patient safety and brand reputation – an unacceptable risk for GMP-compliant supply chains.
“Our priority has always been to deliver products that meet our customers’ high expectations,” explains Katarzyna Zecer-Gołaszewska, partner at A-Z Colour. “However, in a dynamic market that does not forgive mistakes, ensuring absolute reliability at every stage of production was a real challenge.”
A-Z Color was faced with the task of finding a future-proof, automated solution that would combine 100% reliability with maximum production speed.
No compromises on quality
A few years ago, A-Z Color implemented its first automated print inspection systems and evaluated their performance in long-term use. The selection criteria were simple and included ultra-precise detection, stable 24/7 performance, seamless integration, user-friendly design and reliable operation.
“When selecting the right product, it is not only the technology and price that matter to us, but also the quality of cooperation,” emphasises Zecer-Gołaszewska. “We need partners who understand our requirements, share our quality standards and provide us with reliable support in our daily production. An evaluation of various quality control systems, taking into account pharmaceutical requirements and GMP guidelines, allowed us to make a clear decision: while competing systems failed in areas critical to the pharmaceutical industry, EyeC systems reliably and consistently detected even the smallest deviations.”
Technology meets practice
The EyeC Proofiler 600 DT offline scanner system was used to check the print pattern, while EyeC ProofRunner Web inline systems were used for 100% inspection on the label printing line. The EyeC Proofiler combines intelligent software with a high-resolution flatbed scanner and enables objective, repeatable quality control of text, colours, graphics, 1D and 2D codes, and Braille. It digitally compares printed products with approved PDF templates, checking both print quality and content accuracy.
Based on this approach, EyeC ProofRunner Web cameras capture every label during the printing process. Each item is fully checked for accuracy, colour accuracy, registration accuracy and positioning accuracy, and then then automatically verified. The system detects and flags errors in real time, so that only error-free products are processed further. All EyeC systems are equipped with pixel-accurate comparison algorithms that detect deviations of 0.1 millimetres, enable real-time analysis at full production speed and automatically compensate for differences in materials and prints. Intelligent contrast analysis also prevents false alarms. If deviations are detected, the system immediately notifies production, precisely locates the deviation and allows operators to make targeted corrections.
By combining offline and inline systems, AZ Colour was able to fully digitise its quality control process. The implementation was completed in record time without interrupting production. After two weeks of technical preparation, including analysis of production lines, infrastructure upgrades and definition of real-world test cases, three ProofRunner Web systems were installed, qualified and tested in a single day with the active support of A-Z Colour’s technologist and maintenance staff. After practical training for operators, the systems were immediately put into production mode. The installation complied with pharmaceutical standards and included approved documentation (IQ/OQ) and training certificates for all operators. “The installation can definitely be described as exemplary,” confirms Zecer-Gołaszewska.
