Fisher Smith Brings Full-Line Cartridge Inspection to New Diagnostics Filling Cell
Corby-based machine vision integrator Fisher Smith has completed a vision inspection system for a new cartridge filling and sealing line at a global diagnostics manufacturer, combining fill-volume verification, foil-seal inspection and print/barcode checking in a single cell.
The line fills a multi-well diagnostic cartridge used in an automated sample-extraction system, with reagents dispensed across nine individual wells before the cartridge is foil-sealed and printed with batch and traceability data. Because the process is used in a regulated diagnostics workflow, every well needed independent verification to a tight tolerance — complicated by the fact the line runs two cartridge variants, with different reagents in the same well positions depending on which is running.
The challenge: nine independent fill levels and on-the-fly variant switching
“The brief wasn’t just ‘find the tall bottle’,” said Reece Donneky, Project Engineer at Fisher Smith. “We were being asked to confirm nine separate fill levels per cartridge, on a line that switches product variant on the fly, without a single manual settings change.”
In regulated diagnostics workflows, dispensing accuracy is critical to downstream analytical validity. Each cartridge features nine separate wells that receive precise volumes of distinct chemical reagents. Because the automated line handles two distinct cartridge variants, the expected reagent type, meniscus, and volume in any given well position changes depending on which variant is running.
Manual inspection or simple presence sensing was impossible at production speed and precision requirements. The manufacturer needed a non-contact, highly repeatable vision system capable of inspecting every single well to tight tolerances, without requiring physical retooling or manual adjustments during product changeovers.
Multi-stage verification in a single integrated cell
Fisher Smith designed and integrated a comprehensive inspection station that validates each cartridge across multiple critical process milestones within a single cell:
- Fill-volume verification: Inspects fill volume immediately after dispensing across all nine individual wells, confirming fluid levels to tight tolerances and identifying any under-filled, over-filled, or missing reagent wells.
- Foil-seal inspection: Checks foil-seal coverage, placement, and seal integrity before the cartridge proceeds downstream to secondary packaging.
- Print & barcode verification: Verifies printed batch codes and barcodes for position, rotation, optical contrast, and legibility, ensuring full readability across the traceability lifecycle.
Changeover between cartridge variants is a single dropdown selection on the HMI. The system reconfigures inspection parameters, camera settings, and lighting automatically without operator intervention.
Traceability, audit logging and two-tier access control
To meet the strict compliance and validation requirements of healthcare manufacturing, the system provides complete digital traceability for every unit produced.
Every inspected cartridge generates a timestamped image, with rejected cartridges additionally logging the specific defect mode for full traceability and audit reporting.
Two-tier operator/administrator access keeps inspection thresholds and recipes strictly under engineer control, alongside secure remote access for the customer’s engineering team to support real-time line diagnostics and monitoring.
The modern vision system: inspector, data logger, and changeover engineer
“Diagnostics and pharma manufacturers are dealing with more product variants, tighter tolerances and heavier documentation burdens than ever,” Donneky added. “The vision system increasingly has to do the job of an inspector, a data logger and a changeover engineer, all at once.”
The line is now in commissioning ahead of full production, providing the manufacturer with high-precision quality assurance and seamless operational agility.
Key takeaways
- Integrated multi-stage cell: Combines 9-well fill volume verification, foil-seal integrity, and batch print/barcode verification in a single footprint.
- Zero-touch recipe changeover: Single dropdown selection automatically adjusts inspection parameters, cameras, and lighting for different cartridge variants on the fly.
- Full compliance & traceability: Generates timestamped images for every cartridge and logs specific defect types for rejected units.
- Secure two-tier access: Separates operator controls from engineering thresholds and provides remote access for central engineering teams.
- Regulated diagnostic standards: Delivers tight-tolerance verification required for automated sample-extraction cartridges.
Frequently asked questions
How does the system verify nine separate fill volumes per cartridge?
The system inspects fill volumes immediately after dispensing, using calibrated optics and tailored lighting recipes to measure liquid levels across all nine wells simultaneously against tight tolerances.
How does changeover work between cartridge variants?
Changeover between variants requires only a single dropdown selection on the HMI. The vision software automatically reloads inspection parameters, camera exposures, and lighting configurations without any manual hardware adjustments.
What checks are performed on the foil seal and batch print?
The foil seal is inspected for complete coverage, positioning, and seal integrity before proceeding downstream. Printed batch codes and barcodes are verified for position, rotation, contrast, and legibility to ensure ISO-grade readability.
How are inspection records stored for compliance?
Every inspected cartridge creates a timestamped image. When a cartridge is rejected, the system logs the specific failure mode to maintain a complete, audit-ready digital quality record.
If your facility manufactures regulated diagnostics, pharmaceuticals, or healthcare devices and requires multi-stage inline vision inspection with automated changeover and full traceability, contact Fisher Smith to discuss your project.