Reducing False Rejects: How EVO CAX Optimizes Reinspection of Ejects in Inline Production

Automated Visual Inspection (AVI) systems play a crucial role in ensuring product integrity, but even the most advanced high-speed AVI systems generate a small percentage of false rejects. These false rejects, or ejects, can lead to unnecessary product waste, machine downtime and increased production costs if not handled efficiently.

The EVO CAX provides an innovative solution: a dedicated, small-scale inspection platform that enables the reinspection of these ejects, minimizing waste and maximizing yield without compromising product quality and the production process.

High-speed AVI systems are essential for large-scale pharmaceutical production, ensuring rapid and accurate identification of defective products. However, these systems tend to operate with stringent defect detection settings to avoid the risk of passing potentially defective containers. This cautious approach results in a certain percentage of false rejects, samples that need to go through reinspection to be sure they are compliant and safe for use. 

Discarding these products outright is not only costly but also unsustainable. Additionally, recruiting and training skilled operators for manual visual inspection (MVI) can be challenging, leading to bottlenecks in quality control processes. The EVO CAX addresses this issue by providing a fully automated, reliable, and operator-independent reinspection process. With its ability to store and recall inspection recipes, the system ensures consistency and efficiency across batches, reducing the need for extensive retraining and operator intervention.

The EVO CAX is designed to tackle the challenges associated with batch variability and false reject management. By providing a second-stage automated inspection for ejects from high-speed AVI systems, it enables pharmaceutical manufacturers to recover viable products while maintaining stringent quality standards.

Key Benefits of Reinspection with EVO CAX:

• Reduction in False Reject Rate: The system lowers the false reject rate ensuring that safe and compliant products are not unnecessarily discarded.
• Cost Savings & Waste Reduction: By rescuing falsely rejected vials, pharmaceutical companies can avoid the financial and material loss associated with discarding viable products.
• Consistent & Reliable Inspection: Unlike manual inspection, which is subject to operator variability, EVO CAX ensures a reproducible and standardized inspection process.
• Human-Inspired Handling: The robotic system mimics manual inspection movements, ensuring gentle and controlled vial handling to protect product integrity.
• Seamless Integration into Production Workflows: EVO CAX’s compact design and flexible fleet concept allow it to be easily integrated into existing production setups, supporting batch reinspection without disrupting overall throughput.

The EVO CAX leverages AI-supported baselines, cutting-edge camera technology, and the WILCO OptiX™ static optical path, eliminating the need for frequent manual adjustments. This enhances inspection accuracy, ensures superior image quality, and accelerates the process of recipe development for new products.

Furthermore, its modular design allows for quick adaptation to different vial sizes (2R–30R) with liquid or lyophilized products, making it a versatile solution not only for the reinspection of ejects but also for clinical and small-scale production environments.