The Danish pharmaceutical company AJ Vaccines, based in Copenhagen, is turning to advanced image processing solutions to further increase efficiency and quality in vaccine production. In collaboration with automation specialist Omron, a proof of concept (PoC) was developed to automate vial counting on an existing production line. The objective was to improve data reconciliation with system data and reduce manual processes. A company representative explained that, as an innovative and forward-looking organization, AJ Vaccines aims to stay at the forefront of technological development by testing new solutions that could enhance its high quality standards.

Data reconciliation as a critical element in pharmaceutical production

Precise reconciliation of production data is essential in pharmaceutical manufacturing. AJ Vaccines uses these processes to meet regulatory requirements and ensure transparency throughout the supply chain. A reliable data foundation is particularly vital in the production of life-saving vaccines.

AJ Vaccines integrates image processing system

To implement the PoC, a test cell was set up featuring the Omron FH-5552 controller, a high-resolution camera, and four light bars. The system uses photometric stereo lighting to accurately capture the contours of the vials. Results are displayed directly on a human-machine interface (HMI), simplifying operation and supporting the validation of the counting process.

Successful test phase with 100 percent accuracy

The system was tested over a four-week period and achieved a one hundred percent success rate in automated vial counting. AJ Vaccines evaluated the results as highly positive and is planning further development of the solution.

By deploying the GxP-compliant FH controller, the pharmaceutical company aims to digitalize processes in a scalable and cost-efficient manner. The collaboration with Omron demonstrates how existing production lines can be retrofitted with intelligent automation solutions without compromising on quality or regulatory compliance.

Sustainable outlook for pharmaceutical manufacturing

The PoC at AJ Vaccines highlights the potential of digital automation solutions in the pharmaceutical industry. The successful integration of the image processing system marks a significant step toward data-driven and transparent production. According to Sam Tilley, Regional General Manager at Omron, companies in life sciences, pharma, and other sectors worldwide are seeking ways to operate more efficiently and with greater data transparency, while maintaining quality. He noted that the PoC at AJ Vaccines illustrates the feasibility of developing cost-efficient retrofit solutions that pave the way for digitalized production processes.