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Pharmaceutical inspection is becoming the bottleneck.
Increasing variability is exposing the limits of traditional systems.
What’s driving the shift:
• Biologics and lyophilized products introduce inherent variability
• High-mix manufacturing is becoming the norm, not the exception
• Regulatory pressure on quality and consistency continues to rise
Where current approaches fall short:
• Manual inspection is inconsistent and difficult to scale
• Semi-automated systems increase speed but reduce reliability
• Traditional automated systems struggle with variability and changeover
Why this matters:
• Elevated false reject rates reduce yield
• Failed AQLs delay batch release and increase reinspection costs
• Inspection is becoming a direct operational and financial risk
What You’ll Learn
• The inspection challenges facing modern pharmaceutical manufacturing
• Current approaches: manual, semi-automated, and automated systems
• Why legacy inspection methods are no longer sufficient
Supercharge Visual Inspection with DAI-50
Enhance product quality and 3x inspection speed
The DAI-50 brings together Dabrico’s 45 years of visual inspection expertise and Boon Logic’s AVIS AI platform to set a new standard of inspection: human-like adaptability with validated, automated performance.
- 60 minutes to train a new inspection recipe
- 90 units per minute maximum throughput
- 99% detection accuracy for particulate and cosmetic defects
Fast and gentle material handling to support any form factor
The DAI-50 uses a brief pre-spin to create a controlled vortex that makes particles easier to detect. This ensures every defect is clearly captured by one of the system’s three high-resolution cameras.
- Adjustable pre-spin for full defect visibility
- Adjustable lighting and vial positioning
- Interchangeable rollers to support any product type
- Configurable for 2 ml - 1,000 ml containers
Configurable optics for maximum visibility
The DAI-50 uses three dedicated cameras, each focused on different parts of the vial to highlight specific defect types. Pre-defined regions of interest (ROIs) guide each camera to the areas where issues most commonly occur, providing clear, targeted insight for accurate inspection.
- Backlit, top-view, and side-view cameras
- 60 FPS
Artificial intelligence-based visual inspection powered by AVIS
AVIS uses an unsupervised learning approach that models normal variation rather than relying on defect libraries or labeled images, allowing it to detect both known and unknown anomalies.
- Near 100% accuracy for all defect types
- <1% false eject rate
- Train new inspection recipes in <60-minutes
Seamless system qualification with audit-friendly documentation.
The DAI-50 follows the standard pharma validation sequence, IQ, OQ, and PQ, but accelerates qualification because AVIS trains directly from a compliant product and creates a frozen, validation-ready recipe.
- Audit-validated qualification process
- Full documentation and qualification support
- < 6 weeks to qualify on average