Optimizing quality control in the pharmaceutical packaging industry with the EyeC 1050 RS

As the world’s leading manufacturer of packaging solutions made of cardboard and paper, the Edelmann Group continuously strives for process optimization along the entire supply chain. When the Edelmann Group, headquartered in Heidenheim, Brenz, Baden-Württemberg, merged the production sites in Wuppertal and Leverkusen into a new site in Burscheid in 2022, the focus of the new production site was on the production of sustainable packaging solutions made of cardboard and paper – such as folding boxes and package inserts – especially for the pharmaceutical industry. In order to meet the increasing demands/requirements for individual and high-quality packaging solutions and package inserts, the merging of the production sites required the further development of the existing quality management system. There was the challenge to combine the existing testing process while also introducing a suitable inspection system for print image control that takes different artworks and printing materials with a grammage of 37 g/m2 up to 450 g/m2 into account as part of the quality control. The aim was to further optimize the testing processes by using a suitable inspection solution. Particular attention was paid to materials with a low material thickness.

The Search for an Innovative Solution

The Edelmann Group was already using the EyeC Proofiler 1067 CS for incoming goods inspection, but decided to upgrade. In close coordination with the EyeC sales team, the previously used swipe scanner was ultimately replaced by the successor model, the EyeC Proofiler 1050 RS, which impressed with its significantly improved precision and higher performance. At the same time, the system was subjected to validation within the framework of internal and external requirements. The system was qualified using DQ, IQ, and OQ, with the validation also taking into account the requirements of 21 CFR part 11 and the Editio Cantor error evaluation list for secondary packaging. Patrick Herminghaus, Quality Assurance at the Edelmann Group, emphasizes: “On the one hand, the solutions offered by EyeC meet the sometimes complex market requirements for the pharmaceutical printing industry, and on the other hand, EyeC support and services have been at a consistently high level for many years. Based on this knowledge and our own positive experiences, we made the conscious decision to continue our cooperation with EyeC and continue to rely on their solutions.”

Improving Quality Control with the EyeC Proofiler 1050 RS

In 2023, the EyeC Proofiler 1050 RS was successfully implemented in the quality control testing processes. Since then, the off-line inspection system has been checking the quality of all types of printed products against the print template. The intelligent algorithm of the robust feed-through scanner compensates for typical fluctuations in the printing process and only shows relevant deviations. The comprehensive inspection of printed products such as printed sheets and package inserts against approved PDF templates enables the Edelmann Group to carry out efficient evaluations, shows precise results and helps ensure the conformity of the printed product.

Thought Through to Phenomenal Results

Overall, the Edelmann Group was able to optimize its quality control with the EyeC Proofiler 1050 RS and thereby increase the efficiency of its work processes. The Edelmann Group has been successfully using the EyeC Proofiler 1050 RS in its quality control for a year now and has already been able to reduce the risk of incorrect classifications and inspection times. By using the system, the evaluation of printed products can be carried out promptly by sampling the proof against the approved print file. The implementation of the system was also able to significantly improve scanning and evaluation times and greatly reduce the number of pseudo-suspicious areas in print image inspection. This early detection of printing errors also made it possible to largely minimize potential costs. By enabling a standardized inspection of printed sheets, regardless of the thickness of the printing material, the EyeC Proofiler 1050 RS ensures a high level of product safety along the entire process chain.

Patrick Herminghaus confirms: “The introduction of the new EyeC Proofiler RS in Burscheid was crucial for the Edelmann Group to continue to deliver high-quality packaging solutions for the pharmaceutical industry with optimal and high-performance systems.” Herminghaus adds, “The precise print inspection and extensive capabilities of the EyeC Proofiler 1050 RS make it an ideal solution for quality control in the pharmaceutical industry.”

Next Steps

Due to the positive experiences and results achieved, the partnership between the Edelmann Group and EyeC GmbH will continue on in to the future. Joint opportunities will be expanded in order to implement significant added value potential for Edelmann customers and to offer them further efficiency increases and quality improvements.