01
Product Overview
The TrueCARE Online Tablet & Capsule Inspection Machine is a state-of-the-art, fully-automatic visual inspection system engineered to ensure the highest standards of pharmaceutical quality control. Developed for the in-line inspection of a wide range of tablets and capsules, this machine combines advanced machine vision technology with industrial-grade automation to detect cosmetic, structural, and printing defects with exceptional precision.
This system supports both single and dual inspection channel configurations, making it ideal for manufacturers with varying throughput requirements. TrueCARE’s design ensures non-contact inspection, preserving product integrity while delivering accurate results at speeds up to 550,000 units per hour.
With seamless integration into production lines and the ability to run 24/7 with minimal supervision, the TrueCARE system represents a leap forward in pharmaceutical inspection reliability and efficiency.
Working Principle
The TrueCARE machine operates on a high-speed machine vision-based non-contact inspection method. Here’s how it works:
- Feeding and Sorting: Tablets and capsules are evenly fed into the system using a vibration-assisted feeding funnel and centrifugal sorting trays. These components are constructed from food-grade materials to ensure hygiene and prevent contamination.
- Multi-Angle Image Acquisition:
- Each unit passes beneath a set of high-speed industrial cameras.
- The camera system includes four prisms arranged to capture the side views via light refraction, and one camera for the top view.
- A vacuum belt conveyor then rotates the product to reveal the bottom surface, ensuring 360° coverage.
- Each tablet or capsule is captured in 5 to 10 images from different angles simultaneously.
- Image Processing:
- These images are analyzed in real-time using industrial computers and AI algorithms trained to detect over 30 types of defects.
- Lighting systems (ring and strip lights) are synchronized with image capture to maximize contrast and clarity.
- Defect Detection:
- Tablets are inspected for issues like half-breaks, chipping, pitting, black spots, color inconsistencies, coating damage, and incorrect printing. (Detailed info. Mentioned in Technical Specification)
- Capsules are checked for deformation, cracks, incorrect assembly, empty filling, foreign bodies, abnormal length or shape, and print quality. (Detailed info. Mentioned in Technical Specification)
- Rejection System:
- Defective or undetected items are automatically rejected using high-pressure Bernoulli air jets.
- The system ensures that only conforming products proceed to the next stage.
02
Applications
The TrueCARE machine operates on a high-speed machine vision-based non-contact inspection method and its applications are:
- Feeding and Sorting
- Multi-Angle Image Acquisition
- Image Processing
- Defect Detection
- Rejection System
03
Standard Features
- High Accuracy & Reliability: Equipped with multiple overlapping CCD cameras and optimized lighting systems, ensuring detection accuracy of ≥40μm.
- Channel Configuration: Offers C1 (single channel) for moderate output (up to 320,000 pcs/hr for φ5mm items) and C2 (dual channel) for high-volume inspections (up to 600,000 pcs/hr for φ5mm items).
- Comprehensive Defect Detection:
- Tablets: detects cracks, coating issues, print loss, mixed tablets, foreign matter, and more.
- Capsules: detects splits, dents, print errors, wrong assembly, size discrepancies, and foreign bodies.
- User-Friendly Interface: A 21.5” industrial touchscreen panel allows intuitive operation, real-time data monitoring, and error reporting.
- Robust Mechanical Design:
- Built with 304 stainless steel and food-safe polymers.
- Modular design with easy part replacement for different tablet/capsule sizes.
- Equipped with vacuum conveyor & lifting mechanism for adaptable inspection.
- Stable 24/7 Operation:
- Powered by Omron PLCs, Basler cameras, and Advantech IPCs.
- Supports unmanned operation when integrated with vacuum feeding units.
- Hygiene and Safety:
- All contact materials are food-grade.
- Includes dust and powder removal at all critical junctions.
- Enclosure equipped with ventilation and safety locks.
04
Technical Specifications
| Parameter | Specification |
|---|---|
| Type of Device | Automatic Table/capsule Visual Inspection Machine |
| Machine Standard | • The Current state of the art GMP Compliance. • European Medicine Agency (EMA) and USFDA Regulations compliance. |
| Rating | IP-65 |
| Product Contact Parts | SS 316L |
| Structure MOC | SS 304 |
| Gasket Seal | PTFE, Silicon, or Viton, Compliance USFDA regulations 21 CFR |
| Non-Product contact parts | SS.304 |
| SS Parts Finish | Ra 0.8 Matt |
| Inspection Principle | Machine vision non-contact inspection |
| Light intensity | less than 3200LX |
| Resolution | VI section ≥ 40μm |
| Rejection | Bernoulli pneumatic rejection |
| Compressed Air | 6 CFM @ 6 Bar |
| Operating Temperature & Humidity | 0 to 35 ℃, RH - 15% to 80% |
| Power | 10 kW, 415V, 50 Hz |
| Tablet Specification | |
| Tablets Type | • Plain Tablet, • Coated Tablet, • Sugar Coated Tablet, • Single Side/Double Side Printing, With Secant Engraving |
| Tablets Size | • Round Tablet: Diameter φ5-12mm, thickness 2-12mm • Special Shaped Tablet: Length 5-21mm width 5-12. Thickness 2-12mm |
| Detection Surface | The All Sides, Top, Back more than 360 degree |
| Defects Detection | • Half grain, Missing Corners, • Deformation, Poor coating, • Pitting, • Black Spots, • Poor Marking, • Side Stains/Different Colors, • Side Coating Damage, • Side Cracks, • Side Drug Damage, • Cracks, Stains, • Printing Loss/Color Infiltration, • Mixed Tablets, • Foreign Body Attachment, • Coating Peeling, • Different Colors, • Adhesion, Etc. |
| Detection Accuracy | 40um |
| Detection Design Speed | Dual Channel: 600,000 Tab./ Hour (based on diameter φ5mm) decreases with size increase Single Channel: 320,000 Tab./ Hour (based on diameter φ5mm) decreases with size increase |
| Capsule Specification | |
| Tablets Type | • Mono color capsules, • Dual Color Capsules, • Soft Gel Capsules, • Capsules with Printing. |
| Tablets Size | #00, #0, #1, #2, #3, #4 capsule |
| Detection Surface | The All Sides, Top, Back more than 360 degrees |
| Defects Detection | • Half Top Concave Defect, • Damage, • Foreign Body, • Black Spot, • Hair, • Different Color, • Irregular, • Half Section, • Fracture, • Deflated Shell, • Split, • Broken, • Wrong Insertion, • Abnormal Length (Long Body, Short Body, Long Cap, Short Cap, Long Sac, Short Sac) • Stains, • Cracks/Notches, • Dents, • Holes, • Missing Printing, • No Printing, • Different Specifications, • Double Cap, • Empty Capsule, Etc. |
| Detection Accuracy | 40 µm |
| Detection Design Speed | Dual Channel: 360,000 Tab./ Hour (based on #4 Capsule) decreases with size increase Single Channel: 180,000 Tab./ Hour (based on #4 Capsule) decreases with size increase |
| Operating Panel | |
| Operating Panel | IPC Touch Screen with 21 CFR Part 11 Compliance • 21.5” Industrial Grade IPC • Multi User levels with user privileges • Audit trail • Alarm history • Electronic records / Print report in Non-editable formats (PDF) • Printout file by Printed by (user ID), Printed date and time, Report name • Including simple batch report. • Batch report should be printed direct from the machine. |
| Bought Out Items | |
| PLC | Omron |
| Servo motor driver | Omron |
| Servo motor | Omron |
| Switch Gear | Schneider |
| Industrial Computer | Advantech |
| IPC | Advantech |
| Pressure Guage | SMC |
| Solenoid Valve | SMC |
| Lens | Basler |
| Camera | Basler |