AIbeat Vision Inspection System for MDI / Nasal Spray Actuators
Executive Summary
A leading global pharmaceutical manufacturer sought to strengthen its quality assurance framework for Metered Dose Inhaler (MDI) and nasal spray actuators at its manufacturing facility. Given the critical role of these actuators in respiratory drug delivery, even minor defects posed risks to product performance, patient safety, and regulatory compliance.
To overcome challenges associated with high-speed production and precise defect detection, the manufacturer evaluated the AIbeat Vision Inspection System developed by SPAN. The implementation enabled consistent, real-time inspection under actual manufacturing conditions, resulting in improved inspection reliability, accuracy, and overall process robustness.
Customer Background
The manufacturer has a strong global presence in respiratory care products, supplying regulated markets worldwide. This manufacturing unit produces MDI and nasal spray actuators that require 100% inspection to ensure functional integrity and adherence to stringent pharmaceutical quality standards.
A strategic focus on innovation, automation, and regulatory readiness drove the decision to adopt an advanced vision-based inspection solution.
Business Challenges
1. High-Speed Production with 100% Inspection
The actuator production line operates continuously to meet high market demand. Manual inspection was not scalable and introduced variability, making it difficult to maintain consistent quality at required production speeds.
2. Detection of Multiple Defect Types
Actuators exhibited a wide range of potential defects, including:
Surface damages and bruises
Cuts, dents, and cracks
Marks and structural deformities
Missing or improperly fitted caps
3. Regulatory Compliance Requirements
Pharmaceutical regulations demand consistent inspection and documented quality assurance. Manual inspection processes lacked robustness and repeatability under high-volume production conditions.
4. Reduction of Human Dependency
Manual inspection increased labor dependency and the risk of fatigue-related errors. The manufacturer aimed to improve efficiency, consistency, and reliability through automation.
Solution Implemented: AIbeat Vision Inspection System
AIbeat was evaluated as an inline, multi-camera vision inspection system designed for full-surface actuator inspection in real time.
AIbeat Vision Inspection System
Multiple cameras were positioned to capture images from different angles, enabling comprehensive 360-degree inspection of each actuator. The lighting setup ensured consistent image quality while minimizing reflections and surface glare.
Inspection Methodology
Inline Multi-Angle Inspection
AIbeat was integrated directly on the production machine. Multiple cameras captured images from different orientations, enabling 360-degree inspection of each actuator without interrupting production flow.
Stage 1 – Good Product Inspection
Reference actuators were used to establish inspection parameters and validate consistent detection of acceptable products.
Stage 2 – Challenge Testing
The system was tested using intentionally defective actuators. AIbeat successfully detected:
Surface anomalies
Bruised and damaged actuators
Cuts, dents, and marks
Missing caps
The system-maintained detection accuracy even in the presence of vibration and displacement.
Results & Outcomes
| Area | Before | After |
|---|---|---|
| Quality Assurance | Inconsistent, operator-dependent defect detection | Standardized, consistent detection of all critical actuator defects |
| Operational Efficiency | Manual or sample-based inspection reducing productivity | 100% inline inspection at full speed with minimal manual effort |
| Compliance Support | Manual processes with limited consistency | Automated inspection aligned with pharmaceutical quality requirements |
Conclusion
The AIbeat Vision Inspection System successfully addressed key challenges related to speed, accuracy, reliability, and regulatory expectations in actuator inspection. By combining multi-angle vision, intelligent defect detection, and inline automation, AIbeat proved to be a scalable and robust solution for pharmaceutical manufacturing environments.
This case study demonstrates how AIbeat can support manufacturers in achieving higher quality standards, improved operational efficiency, and greater confidence in inspecting critical components.
Looking to automate actuator inspection?
Speak with SPAN experts about deploying AIbeat on your MDI or nasal spray production line.