Optimised quality control in pharma packaging

As a leading global manufacturer of packaging solutions made from cardboard and paper, the Edelmann Group continuously strives for process optimisation along the entire supply chain. It recently upgraded its EyeC Proofiler 1067 CS to the newer EyeC Proofiler 1050 RS to augment its quality management system.

Since 2023, the Edelmann Group has been using the EyeC Proofiler 1050 RS offline inspection system. It effectively checks the quality of all types of printed products against the original artwork

In 2022, the Edelmann Group, headquartered in Heidenheim, Brenz, Baden-Württemberg, merged its production sites in Wuppertal and Leverkusen into a new site in Burscheid. The new production site focuses on the production of sustainable packaging solutions made from cardboard and paper – such as folding boxes and package inserts – particularly for the pharmaceutical industry.

To meet the increasing demands for individual and high-quality packaging solutions and package inserts, the group’s existing quality management system needed to be developed to accommodate the merger.

It was a challenge to combine the existing testing process while introducing a suitable inspection system for print image control which considers different artworks and printing materials with a grammage ranging from 37g/m² to 450g/m² as part of the quality control process. The aim was to further optimise 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

Although Edelmann was already using the EyeC Proofiler 1067 CS for incoming goods inspection, the group decided to upgrade. Working closely with the EyeC sales team, the previously used pull-through scanner was ultimately replaced by its successor model, the EyeC Proofiler 1050 RS. This model impressed the group with its significantly improved precision and higher performance.

The new system was subjected to validation within the framework of internal and external requirements. The EyeC Proofiler 1050 RS 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, emphasises: “On the one hand, the solutions offered by EyeC meet the sometimes-complex market requirements for the pharmaceutical packaging printing industry. On the other hand, EyeC’s 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 decision to continue our cooperation with EyeC and continue to rely on their solutions.”

Improving quality control

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 pull-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 optimise its quality control with the EyeC Proofiler 1050 RS, increasing the efficiency of its work processes. The 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.

With this system, the evaluation of printed products can be carried out promptly by sampling the proof against the approved print file. Its implementation has also capabilities of the new system make it an ideal solution for quality control in the pharmaceutical industry.”

A partnership with future prospects

Due to the positive experiences and results achieved, the partnership between the Edelmann Group and EyeC will continue into the future. Joint opportunities will be explored in more detail to implement value-adding potential for Edelmann’s customers while offering the group increased efficiencies and quality improvements. • significantly improved scanning and evaluation times and greatly reduced the number of pseudo-suspicious areas in print image inspection.

With the early detection of printing errors, it is possible to minimise potential costs on a large scale. By enabling the standardised inspection of printed sheets, regardless of the thickness of the printing material, the EyeC Proofiler 1050 ensures a high level of product safety along the entire process chain.

Herminghaus adds: “The introduction of the new EyeC Proofiler RS in Burscheid was crucial for the Edelmann Group to continue to deliver high-quality packaging solutions to the pharmaceutical industry using optimal and high-performance systems. The precise print inspection and extensive