AI-based Automatic Visual Inspection
Machine for Vials and Syringes
Enhance product quality and 3X inspection speed with the DAI-50
The DAI-50 brings together Dabrico’s 45 years of automated 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 an inspection recipe
90 units per minute at maximum speed
99% detection accuracy for particulate and cosmetic defects*
A Superior Automatic Vision Inspection
Machine for Vials and Syringes
A Superior Automatic Vision Inspection Machine for Vials and Syringes
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 camera
- Top-view camera
- Side-view camera
- 60 frames per second
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.
This method naturally adapts to real-world variability in molded glass vials, powders, lyo cakes, and other challenging products. In 45 minutes and four simple steps, a new inspection recipe can be created.
- 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 compliant product and creates a frozen, validation-ready recipe.
- Audit-validated qualification process
- Full documentation and qualification support
- <6-weeks to qualify on average
Never miss a defect, even with
difficult-to-inspect products
Never miss a defect, even with difficult-to-inspect products
AUTOMATIC VIAL INSPECTION
Freeze-dried products
Lyophilized products, such as vaccines and certain antibiotics, pose unique inspection challenges because natural variation in appearance can closely resemble true defects. By learning normal product variation directly from compliant units, the DAI-50 avoids rigid defect rules and instead flags only meaningful anomalies—delivering reliable detection without mistaking acceptable variability for defects.
AUTOMATIC VIAL INSPECTION
Milky products
Camera-based inspection is well suited for opaque or milky formulations like propofol, where inherent variability can obscure true defects. By modeling normal appearance from compliant product and combining controlled imaging, rotation, and optimized lighting, the DAI-50 improves detection accuracy while minimizing false rejects driven by acceptable product variation.
AUTOMATIC VIAL INSPECTION
Bubble-prone products
Protein-based formulations often produce bubbles that closely resemble defects during inspection. By learning normal bubble behavior from compliant product, the DAI-50 distinguishes harmless bubbles from true contaminants, improving inspection accuracy while reducing unnecessary rejects.
AUTOMATIC VIAL INSPECTION
Suspensions
Suspended products like insulins and certain vaccines are more difficult to inspect than clear solutions due to inherent visual variability. By combining controlled rotation with optimized imaging and learning normal product behavior from compliant units, the DAI-50 makes true contaminants easier to detect without increasing false rejects.
AUTOMATIC VIAL INSPECTION
Water-like products
Clear, water-like solutions such as vaccines or GLP-1 products require extremely sensitive inspection to detect small particulates. By learning normal optical behavior from a compliant product and combining high-resolution imaging with configurable lighting from multiple angles, the DAI-50 delivers reliable detection with minimal false rejects.
Train a new Visual inspection recipe
in minutes
Train a new inspection recipe in minutes
The first step in creating a new inspection recipe in AVIS is to record 500 pre-inspected compliant units, covering normal product variations like powder disposition, bubbles, fill level, glass molding, and more. AVIS uses three cameras, capturing hundreds of images from the top, inside, and outside of each unit at 30 frames per second per camera.
After recording, configure regions of interest (ROIs) for all three cameras. Since the units rotate 360 degrees, ROIs can be positioned in areas prone to defects, including easy-to-inspect features like the side wall and shoulder, as well as challenging areas like the vial base, oblique views of lyo cakes and powder, and tamper-evidence seals.
AVIS uses Boon Logic’s unsupervised machine learning algorithm, Boon Nano, to learn the normal variation for each Region of Interest (ROI). A learning curve tracks the model’s progress for each ROI. Initially, the curve is steep as AVIS learns significant variations, but it levels off toward the end, indicating that most normal variations have been integrated into the recipe. Ten unique models are trained, one for each of the 10 ROIs.
In run mode, AVIS makes 100,000 machine learning inferences per vial. Anomalies outside the learned normal variation trigger a spike in the anomaly index, indicating a potential defect. AVIS determines whether a unit is defective within milliseconds, triggering actions like ejecting the unit, stopping the conveyor, or flashing a light. The defect’s video frame, with the exact location highlighted, is displayed and archived for trend analysis.
Reimagine Automated Visual Inspection with the DAI-50
The future of optical inspection isn’t about choosing between human judgment and machine speed. It’s about combining both. The DAI-50 delivers an AI-powered inspection system that brings consistency, adaptability, and precision to modern quality control.
Traditional machine vision inspection systems rely on rigid rules and predefined defect categories. The DAI-50 takes a different approach to defect detection. It learns what “good” looks like and flags anything outside that pattern, enabling more reliable vision quality across real-world production variability.
This transforms quality inspection systems by delivering:
- More accurate detection across complex products
- Consistent quality control without human variability
- Scalable performance for high-mix, low-volume environments
The result is a higher standard for machine vision inspection. One that elevates the inspection process from start to finish.
