A precise look at pharmaceutical processes: Intelligent camera systems in use

End-to-end tracking: How overview cameras secure production

Especially after error messages or alarms, pharmaceutical manufacturers must be able to understand exactly where a glove was reached and how long the procedure took. To this end, the overview cameras record all interventions in the production process. Waldemar Mayer, Group Leader Development Robotics & Digitalization at Optima Pharma, explains the principle, "All video recordings are first backed up in a ring memory. Without any interventions or errors, they are automatically deleted. However, if errors or manual intervention occur, an automatic mechanism ensures that the relevant recordings are permanently stored."

This technology facilitates the subsequent assessment of a product's pharmaceutical and regulatory compliance. If deviations occur, the recordings enable a targeted error analysis. In addition, this system contributes to more objective documentation, as it provides a visual complement to the previously required written log by a second operator. Another advantage is that the live transmission of the recordings can be activated at any time – for example, directly to the production manager's office or to other locations.

Real-Time Error Analysis: High-Speed Cameras Optimize Process Safety and Quality

High-speed cameras are used where processes run particularly fast or are highly critical from a pharmaceutical point of view. This includes the filling and sealing of containers as well as the sorting of stoppers. For example, if a filling needle is dripping, the cause could be faulty suction, needle movement, or some other phenomenon. The images help to identify the exact source of the error and to rectify it in a targeted manner.

"Sometimes a machine goes into alarm mode and indicates an error that is not the actual cause of the malfunction," explains Marcel Klimmer, Product Manager at Optima Pharma. Here, too, the recordings are first stored in a ring memory. As soon as an alarm is triggered, the system permanently stores a defined time period of video material. This makes it possible to understand not only the error itself, but also its origin – which makes error analysis much easier and faster. 

The two camera systems complement each other ideally and enable comprehensive, internal error analysis. Meanwhile, pharmaceutical and regulatory compliance can be documented efficiently and automatically. Companies benefit from improved process reliability, less downtime, and optimized quality control.

Optima currently offers 14 digital products in its digital service portfolio IPAS (Intelligence Production Assistant Services). These digital solutions ensure maximum security, are part of a comprehensive innovation process and are specifically geared the challenges by customers.