Real-world examples, cost breakdowns & smarter inspection systems
In pharmaceutical manufacturing, the packaging end is often the final checkpoint before product release — and also one of the most vulnerable to human error. Manual inspections are still common, but they bring inconsistencies, inefficiencies, and costly risks.
This article breaks down:
- Where and how human errors happen
- The real cost of manual inspection
- How Jekson Vision’s BISmart, TiSmart, and CodeQuest systems drastically reduce error, cost, and compliance risk
Where Human Errors Happen Most: End-of-Line Risks
Despite stringent SOPs, pharma operations see common issues like:
| Inspection Area | Typical Human Errors |
| Tablet & Blister Checks | Missed, chipped, broken, color variation, empty pockets, size/shape mismatch |
| Carton Checks | Leaflet mix-up, wrong product, damaged packaging |
| Labeling & Serialization | Wrong batch/expiry, misaligned or missing labels, unreadable or duplicate codes |
Even highly trained operators can miss defects due to fatigue, repetition, or distraction — especially over long shifts.
Cost Breakdown: The True Price of Manual Inspection
Let’s evaluate a realistic scenario.
🔹 Blister Line Output: 120 blisters/min
→ 7,200 blisters/hour → 57,600 blisters/8-hour shift
🔹 Manual Setup:
- 6 operators across 3 shifts
- Avg. salary/operator: ₹20,000/month
- Total monthly labor cost: ₹1,20,000 (excluding training, rework, supervision, etc.)
🔹 Human Inspection Accuracy: ~98%
→ 0.2% error rate = 115 defective blisters/day
→ Over 34,000 faulty packs annually
That’s not just lost product — it’s a regulatory risk, especially in export markets.
How Automation Changes the Game
Jekson Vision’s smart inspection systems provide machine-precision, zero-fatigue inspection at high speeds — with full traceability and compliance built in.
- BISmart + TiSmart – For Tablet & Blister Inspection
Ideal for: Tablet and capsule lines with blister packaging
- Detects:
- Broken, chipped, empty, deformed, or wrong-color tablets
- Empty or double-filled blister pockets
- Size and shape mismatches
- Works seamlessly with PVC/Alu, Alu/Alu formats
- Offers auto-rejection, batch audit logs, and regulatory compliance reports
Eliminates dependence on human visual inspection.
Accuracy: >99.9%, throughput up to 600 blisters/min.
- CodeQuest – For Serialization & Code Verification
Ideal for: Cartons, bottles, shippers, labels
- Verifies:
- 2D DataMatrix, GTINs, barcodes, expiry dates
- Serialization and aggregation integrity
- Catches:
- Misprints, duplicate codes, unreadable or wrong labels
- Supports compliance with DSCSA, EU FMD, DGFT, ANVISA, and more
Ensures every pack is traceable, compliant, and export-ready
Auto-rejects faulty packs without interrupting production flow.
Manual vs. Machine: A Smart Comparison
| Aspect | Manual Inspection | Automated Systems (Jekson) |
| Accuracy | ~98% | >99.9% |
| Speed | 200–300 packs/min | Up to 600 packs/min |
| Labor Cost (monthly) | ₹1,20,000+ | One-time CapEx, low OpEx |
| Fatigue/Error Drift | High | Zero |
| Compliance Readiness | Partial/manual | 100% digital & auditable |
Trusted by 100+ Countries
Jekson Vision’s end-of-line packaging automation solutions are trusted in over 100 countries, from the world’s largest pharma manufacturers to growing regional exporters.
We don’t just sell machines — we partner from consultation to installation and beyond, offering:
- Hardware + Software from a single source
- Line integration support
- Regulatory consultation
- Post-installation service and upgrades
Final Word: Automate Where Risk is Highest
If your final quality check still relies on humans, you’re accepting unnecessary risk.
As global regulations tighten and product complexity grows, automation is no longer optional — it’s the foundation for safe, compliant, and scalable operations.
👉 Talk to Jekson Vision
Want to eliminate inspection errors and improve your packaging reliability?
Contact for a no-obligation consultation on how BISmart, TiSmart, and CodeQuest can transform your packaging lines.
