Leuze electronic

proCHECK industrial image processing systems

for pharmaceuticals and general packaging technology
 Leuze electronic

A partner to rely on
Customer-oriented
thinking
All our thoughts and actions
revolve around providing the
best possible benefit for our
customers, based on decades
of experience in their respective
fields and knowledge of their
application requirements.

A member of the Leuze Competence and Quality Consultancy and

Group of Companies with a continuity service
workforce totalling over 1600, High-precision production
Leuze electronic has been Success in today's tough processes, a long-established We see our role as that of a
setting standards in the field competitive environment is Quality System and, first and partner to our customers,
of industrial optosensor tech- determined by innovation, foremost, a quality-conscious offering support for every
nology for more than 4 deca- productivity and the assurance workforce are the cornerstones application – from the initial
des. The product spectrum of absolute quality in the long of the best possible product planning stage through to
ranges from photoelectric term. These qualities call for a quality. The Leuze electronic trouble-free operation and
sensors through optical partner who can be relied on – at Group companies are certified beyond. Part of our compre-
systems for industrial safety the consultation stage, during to ISO 9001. hensive service package is a
and identification to intelligent delivery and also after installa- 24-hour customer hotline.
image processing systems. tion and commissioning. Global presence

Innovation and Wherever our products are

research in use, we are there with the
necessary back-up. Around
Leuze electronic's key area of the globe, in every major
competence lies in the deve- market and in a wide variety
lopment and manufacture of of sectors.
optical sensors for almost every
sphere of industrial automation.
We have set pioneering new
standards and registered ground-
breaking patents in this field.

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 Leuze electronic

C O N T E N T S
Pharma-
ceuticals 4

Cosmetics 5
Focus on production processes
Food 6 Typical applications
Machines learn how Sector-specific
to see system solutions ■ Presence and completeness
check
Beverages 7 proCHECK from Leuze repre- Leuze proCHECK can be ■ Position recognition and
sents the future of quality assu- supplied for two areas of dimensional measurement
rance: A comprehensive application: ■ Colour image evaluation
Tobacco 8 system for the monitoring, ■ proCHECK ECO is the right ■ Image and pattern compa-
documentation and safeguar- solution for industrial use rison
ding of automated production ■ proCHECK PHARMA can ■ Identification (CCV,
sequences based on a highly- also be validated according OCR Bar code, Pharmacode
Printing 9 developed digital image pro- to FDA regulations (GMP, Data matrix
cessing for the inspection of a GAMP 4) and fulfils FDA ■ Print quality control
Specifi- wide range of different product requirements according to
cations 10 parameters. 21 CFR, Part 11. Up to 3,600 inspections per
minute (full frame mode) per-
100 per cent Intelligence and fast mit comprehensive monitoring
reliability for your even at high process speeds –
application proCHECK carries out even enhanced by software with
complex control tasks in the integrated learning capability
proCHECK is an intelligent wink of an eye. which can be configured with-
image processing system out any previous programming
offering wide scope for experience.
applications. This is a solution
which also lends itself to Modular structure
situations in which total permits individual
inspection and documentation solutions
are mandatory requirements.
Because proCHECK only proCHECK is a fully modular
knows one quality standard – system. Depending on the
which is 100 per cent. chosen upgrade version, it is
capable of controlling up to 12
monochrome or colour came-
ras. For highest demands in
colour detection, different
colour cameras are available.

FA2 ST The software tools can be

used in any optional combina-
tion and are so simple to ope-
The more intelligent
software tools rate that trouble-free adjust-
A highly-developed self-learning ment to new or modified pro-
mode permits automatic cesses is guaranteed. Which
adjustment to changing
not only ensures flexibility but
circumstances. As a result,
FA2 ST tools permit reliable provides you with the assur-
evaluation of complex processes ance of having made a safe
even at ultra-high speeds.
investment.

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 Leuze electronic

proCHECK in the pharmaceuticals industry

When it comes Extreme speed,
to the packa- 100% reliability
ging of pharma-
ceutical products, there is proCHECK PHARMA is able
no scope for compromise in to take up to 600 blister pack
terms of quality. Here, 100% inspections per minute easily
inspection is mandatory, in its stride: Optimum condi-
backed up by comprehensive tions for the high cycle rates
documentation – and this occurring in the pharmaceuti-
applies even where extreme- cals industry.
ly high process speeds are
involved. A highly demanding Comprehensive
task, and one for which monitoring of all pro-
proCHECK PHARMA offers duct characteristics
the ideal conditions.
Whether you wish to monitor
the correct filling of each indi-
vidual blister pack or check
the inscription, pharmaceutical
code and insert sheet –
proCHECK PHARMA performs
all the required inspection
tasks, documents the entire
inspection process and is also
optionally able to provide any
required statistical information
relating to output and downtime
for the entire production line.
FDA
Recognition approval
unlimited
The American Food and Drug
Blister packs come in an Administration (FDA) is known
almost endless variety of to be the strictest authority for
formats and versions. The the monitoring of drug and
optical scanning system used medicine manufacture.
CBP by proCHECK PHARMA
works just as reliably with alu-
proCHECK PHARMA offers
full validation capability and
Color Blister Pack permits a
comprehensive check of blister
minium as with white or trans- complies with FDA directives
pack contents. The checks per- parent plastic blister packs. GMP, GAMP 4 and 21 CFR
formed provide information on Reliable recognition of the Part 11. The regulation 21
completeness of filling, size and
tablet colour and shape per- CFR Part 11 governs pass-
position of tablets, fragments or
defects, mixtures, wrong colours mits filling errors to be reliably wordprotected access (elec-
etc. eliminated. tronic signatures) and mani-
pulation-proof storage of elec-
tronic records.

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 Leuze electronic

proCHECK in the cosmetics industry

At the upper end Recognition and veri-
of the cosmetics fication of inscriptions
market, particu-
larly, the value of products is proCHECK is also designed to
frequently equated at first permit the reliable acquisition
glance with the perfection of product data such as article
and quality of the outer pak- number, batch, manufacturing
kaging. This situation calls date and sell-by date.
for no-compromise monito- Irrespective of whether these
ring of all characteristics are in the form of plain text or
which determine dot code.
quality. proCHECK ensures
that only products in absolu- Ultra-high speed plus
te pristine condition ever reliability
find their way onto the shelf.
The system is capable of
completing up to 60 scans per
second, allowing it to cope
easily with even extremely
high process speeds.
proCHECK can be used, for
example, to check correct
label positioning, reliable
gluing of the box and also
print quality – fully automati-
cally and on every single

OCV product.

Safe not sorry

Optical Character Verification is
an intelligent tool with
learning capability for the Has the correct number of
detection and verification of
tablets been packaged? Was
imprints applied using ink jet or
thermal transfer printers, the right vial used? Is the
laser inscriptions etc. filling level correct? Is the
pack undamaged? proCHECK
DMV ensures that only flawless
products can ever reach the
Data Matrix Code Verification shelves, indicating detected
reads 2D codes (ECC 200) with
up to 3,000 scans per minute.
faults in colour.

PCR
The Pharmaceutical Code Reader
reads and verifies pharma-
ceutical codes.

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 Leuze electronic

proCHECK in the food industry

Consumers Clear indication of
tend to equate sell-by date
the quality of
packaging directly to the An essential feature of food
quality of the product. retailing is the sell-by date.
Even the slightest imperfec- Not only does the date have
tions influence purchasing to be printed on each item of
behaviour, irrespective of packaging, it must be correct
whether these actually bear and also easily legible. All
any relation to the condition factors which proCHECK is
of the contents or not. capable of monitoring in frac-
Reason enough to play it tions of a second.
safe with reliable packaging
inspection. proCHECK the visual
"taster"
Foods that are seal welded
call for particularly stringent
inspection. After all, no custo-
mer will touch a food product
with a damaged or faulty seal.
The digital image processing
facility of proCHECK checks,
for instance, whether the weld
seam is intact all round,
wide enough, free of bubbles
or trapped foreign bodies.

Quick change for

maximum flexibility
Flexibility is indispensable in
this day and age. In the food
industry, particularly, with

SMS its huge variety of product

and packaging types. With
Single Module Source is a tool proCHECK, resetting is simply
for the reliable detection of a question of a few mouse
objects with defined
characteristics.
clicks. The inspection parame-
ters for a variety of products

BLOB can be stored and accessed

at any time.
This tool permits the complex
analysis of geometrical product
characteristics.

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 Leuze electronic

proCHECK in the beverages industry

The demands Going with the flow
made on a
system for qua- proCHECK ensures that the
lity assurance are as many demands of quality assurance
and varied as the range of never cause a bottleneck.
drink products and their The system is capable of
different packaging types. keeping continuous pace with
Faced with this enormous modern filling plants, checking
variety, proCHECK is an up to 3,600 bottles per
intelligent system capable of minute.
working substantially faster
and more reliably than Mixed production
humans. well in hand
Does the packaging match the
product? Has the right label
been applied to the bottle? Is
the cap correctly fitted? Is
there a straw glued onto every
carton? Has the pallet been
loaded with the right product
mix? All questions to which
proCHECK can provide a
precise answer. For each and
every packaging unit.

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 Leuze electronic

proCHECK in the tobacco industry

Tobacco Quality where
products are millimetres count
meant for pure
enjoyment. A pity for the During manufacture, it is
enjoyment to be spoilt essential for each cigarette to
because the packaging or look just like the next. The
cigarettes are faulty. length and angle, for example,
proCHECK is a universal as well as adhesion and the
inspection system for a length ratio of the filter to the
sector in which a large cigarette all have to be just
number of details make a right. The image processing
decisive difference. system proCHECK is able to
keep pace with the shortest
cycle times, detecting even
minimal deviations from
standard.

Shape and colour

fully under control
When it comes to packaging,
it is decisive that each indivi-
dual pack of cigarettes leaving
the factory is flawless. The
imprint must match the brand,
and must be free of any faults.
The shape and number of
cigarettes must be right, and
the right customs sticker must
be present. proCHECK acts as
the eye of the packaging
plant, and no errors are
permitted to pass unnoticed.

CPV
Component placement verifica-
tion detects, for instance, mis-
sing products and incorrectly
applied labels. It measures
dimensions, scans edges, chek-
ks positions etc.

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 Leuze electronic

proCHECK in the printing industry

Faulty printed Quality inspection
matter causes under time pressure
annoyance,
extra work and additional Today's high-speed printing
costs. These knock- presses call for continuous
on effects can only be monitoring of the register and
avoided if it is possible to print face. proCHECK supplies
check as early as the the computing speed and
production stage that each analytic capacity to ensure
individual copy is free of 100% monitoring during the
errors. This is a complex printing process.
task which proCHECK
tackles with high-resolution Continuous label
image processing. control
When printing labels, perfec-
tion in every detail and minimal
resetting times are decisive.
proCHECK ensures both these
factors, reliably safeguarding
print quality by a comprehen-
sive optical inspection.

Assembly with all-

round proCHECK
A large number of error
sources can occur during the
assembly process. proCHECK
inspects the positioning and
sequence of individual sheets,
ensures the correct language
version and monitors print
quality – for every single copy,
with absolute reliability.

PQV
Print Quality Verification permits
the reliable detection of a num-
ber of different error types during
the printing of text and pictures.

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 Leuze electronic

proCHECK – visual quality assurance

High-performance Scaling capability proCHECK Specifications
hardware and system Basic unit Industrial PC (PCI bus) in lockable 19"
integration housing with fan
The hardware platform for Processor Current Pentium processor
proCHECK is provided by Every proCHECK can be Graphic card XVGA
high-performance industrial upgraded – from the stand- Frame grabber Vision processor on-board. Up to 4
PCs running under Windows. alone solution up to the (product- monochrome or colour cameras, dependent on
dependent) frame grabber type. Buffer memory.
Each system is capable of integrated universal solution Synchronous, asynchronous or mixed mode.
accommodating up to three with Ethernet networking and Storage medium Customary size hard disk.
frame grabber boards. a central control system, Disk drive 3.5" / 1,44 MB
Depending on the product, up providing bidirectional data CD drive
to four monochrome or four communication to the produc- Interfaces 2 x enhanced IDE, 2 x serial (RS 232C)
1 x parallel, 1 x fast ethernet.
colour cameras can be con- tion control system as well as
24 digital inputs/outputs (optoisolated,
nected to one frame grabber the integration of hardware 24 V), optionally 48 or more.
board. Optional other periphe- components via a field bus. Optionally Interbus-S or PROFIBUS DP.
rals such as bar code readers, Keyboard, mouse PS/2 (Logitech, cherry)
scales etc. can also be inte- Validation capability Monitor XVGA,
integrated monitors or LCD displays available.
grated into the system. to GAMP 4
Operating system Windows
Operating 110 V ↔ 240 V @ 47 Hz ↔ 63 Hz
Intelligent software Part 11 of the Code of Federal
conditions 0 °C ↔ 40 °C, 10 % ↔ 90 % humidity
tools Regulations (CFR) defines (non-condensing)
regulations for the storage and Standards IEC-950, IEC-204 (EN-60950, EN-60204), CE
proCHECK's software is management of electronic
based on a whole series of quality-relevant records in
FA2ST tools (see right), which drug manufacture.
are configured to fulfil certain proCHECK PHARMA offers
identification and recognition validation capability in line
functions. These software with GAMP 4, so ensuring
modules with their learning reproducible, reliable 100 %
capability permit selective control of quality characteri-
adjustment to individual stics.
application requirements.

Graphic user Industrial PC expert with touch-

proCHECK Specifications screen and TFT display (optionally)
interface Camera type Monochrome (8 bit) or colour
Resolution NTSC (typ. 640 x 480 pixel),
Parameterisation of the HR (typ. 1290 x 1024 pixel)
inspection system is performed Picture Progressive scan cameras:
simply using an interactive recording 50 Hz or 60 Hz
user interface with menu Exposure time min. 62 µs
prompting. The operator Lens mount C-mount
receives support when setting Light sources All standard commercially available light
characteristic extraction para- sources (VIS/IR/UV, pulsed/ continuous,
directional lighting/backlighting,
meters by immediate visuali- diffusive/directed/telecentric) as well as Industrial PC economy in
sation directly on screen. special light sources 19” housing (standard)

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 Leuze electronic

proCHECK – combining high-speed and intelligence

Function FA2ST-Tools Description

Object CPV Edge scanning, also in subpixel and

gauging continuous tone area, object gauging, position
control, check of straightness and angles
Gauging GAUGE Simple tool for a fast measurement of objects and
checking their tolerances.
Measurement of RAD Measurement of radius and identification of objects.
radius, referencing Determination of the position (center) of circular objects.
Checking CONTOUR Control and identification of any shape by up to 500
shapes detectors. More than 20 filters integrated.
Characteristic SMS Object identification, characteristic referencing,
referencing search for characteristic symbols or patterns
Angle ANG Referencing of objects by their angle and pivot point.
measurement Can be used as reference for other tools for the
relocation of the region of interest.
Corner CNR Determination of the position, referencing and
reference alignment of objects.
Search area LOCATE Definition of search areas for tracking
definition characteristics with shift and rotation compensation
Presence BLOB Surface control (e.g. pores, scratches)
checking completeness check and object classification
Counting CNT Counting of objects, checking for presence.
More than 20 filters integrated.
Masking MASK Masking irrelevant image information using
simple geometrical shapes
Logic MATH Logic, arithmetic or comparative operations,
operations string functions, formula editor etc.
General VisSCRIPT Combining of results and complex inspections,
operations realisation of sequential tasks, display of messages etc.
Communication COM Communication tool for serial interface (RS 232-C)
Colour CLR Inspection for missing or surplus colours
recognition
Colour blister CBP Colour blister inspection to monitor size,
inspection shape, missing tablets, fragments, mixing
Colour blister CCP Controls coloured or multi-coloured objects for their
inspection of presence and for completeness.
round shapes
Print quality PQV Analysis of printed information, complex image
monitoring patterns or product deviations
Optical character OCV Inspection of printed characters or strings of
verification characters from ink jet or thermal transfer printers etc.
Character OCR_DM Reading and verification of characters or strings of
reading characters, also well suited for DOT codes.
Reading BAR CODE Bar code reading like EAN 8, EAN 13, Code 39 (also
bar codes with checksum or extended ASCII), Code 128, 2/5
Interleaved, UPC-A, UPC-E and UPC-A&E, Codabar
µPDF 417, PDF 417, RSS-Codefamily, Composite A,
Postnet, Planet Code
Reading pharma- PCR Reading pharmaceutical codes
ceutical codes
Reading DMC DMV Data matrix code reading (ECC 200)
codes
Configuration of Security Multi-hierarchy Security Manager to release
access entitlement Manager individual functions, break-time lock
Configuration of Screen Screen configuration, statistics counter,
user interface Manager function keys, faulty image memory, running time display

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 Leuze electronic
Leuze electronic GmbH + Co. KG
P.O. Box 11 11, D-73277 Owen/Teck
Tel. +49(0)7021/ 573-0,
Fax +49(0)7021/ 573-199
E-mail: info@leuze.de, http://www.leuze.de

A qualified partner in the field of...

...detection
Standard sensors in cubic design Contrast, colour, luminescence scanners
Cylindrical sensors Fibre optic amplifiers
Measuring sensors Double sheet/glue joint monitoring
Forked photoelectric sensors Accessories

...identification
Bar code readers Bar code positioning systems
Data matrix code readers Optical data transmission systems
Hand-held readers Laser distance measuring devices
RF identification systems Industrial machine vision

...protection
Safety light curtains Safety relays and interfaces
Multiple light beam safety devices Sensor accessories and signal devices
Safety laser scanners Measuring light curtains
Safety interlocks Service for all aspects of machine safety

For quick, simple sales and service information go to...

GB 140/02-01/06 50034032

...www.leuze.de