Ask the Expert: Product Inspection, Part Two; Automated Product Inspection and Cold Chain Considerations

In this episode of Ask the Expert, Dirk Margosch, Vice President Visual Inspection, Assembly & Secondary Packaging at Vetter Pharma-Fertigung GmbH & Co KG, addresses the benefits of automating visual inspection, which include increased efficiency and accuracy, and what goes into the cost versus benefit of automating inspection of small batches.

“[T] he decision to continue manual inspection for small batch sizes involves several considerations,” says Margosch. “So, costs versus benefit, automated inspection systems can still have high upfront costs for small batch sizes. The return on investment maps may still not justify the expenses if the volume does not vary in automation. [One should] evaluate the cost effectiveness of automating small batches versus manual inspection, [and] if possible, conduct a pilot test for automated inspection on the product to evaluate its principal effectiveness and efficiency before fully committing to automation.”

In this episode, Margosch also discusses how cold chain requirements can be maintained during visual inspection. “Maintaining the cold chain for parameters is critical to ensure product stability, especially when visual inspections [that are] typically performed at room temperature,” says Margosch. “Several strategies are available to assure that the cold chain is maintained during inspection, so [one should] develop comprehensive standard operation procedures that outline the processes for handling, storing, transport, and visual inspection that all require cold chain management, include specific protocols for the transfer of products from cold storage to room temperature. [One should] ensure that these procedures are followed and documented. [One should] consistently implement a robust temperature monitoring and alert system for the entire cold chain, that means for both refrigerated transport and cold storage itself, but ensure also a temperature-controlled and monitored transport from cold storage to room temperature all the way … inside the inspection rooms and back, and very important, limit the duration that products are exposed to room temperature during the inspection processes.”

Click the video above to watch Dr. Margosch answer the following questions:

“My company is looking to move from a manual to a fully automated final product inspection method. However, although we manufacture mostly large batch sizes of product, some of our clients require small batch size production for some of their products. Should we continue to inspect those products manually?”

“My company is looking to develop a product that needs to be stored at a cool temperature. How can we assure the regulators that the cold chain is maintained during visual inspection?”

About the Expert

Dirk Margosch is Vice President Visual Inspection, Assembly & Secondary Packaging at Vetter Pharma-Fertigung GmbH & Co KG. Since joining Vetter in 2008 as head of automated visual inspection, Margosch has promoted to managing the visual inspection department and, from 2021, overseeing all non-aseptic production, including assembly and secondary packaging.

Margosch joined Vetter in 2008 as head of production overseeing process implementation, product-specific qualification and operation of automated visual inspection systems, until he was given the opportunity to manage the entire visual inspection department including both, manual and automated visual inspection. Since 2021, he has been responsible for non-aseptic production, which encompasses automated and manual visual inspection, assembly, and secondary packaging.

Ask the Expert Video Series

Welcome to the Ask the Expert video series. This series is an extension of the PharmTech Group’s long-running print column in which industry experts answer common quality and regulatory questions from the industry. This new video series will expand on topic areas to include development and manufacturing concerns to help those working in the industry better understand bio/pharmaceutical requirements. Have a question you would like answered? Send it to PTProjects@mmhgroup.com, and it may appear in a future episode or print column.

We hope you enjoy the discussion!