AIM5 series: a dynamic development with new features

Two decades make for an eventful career: in the course of its history, Syntegon’s AIM5 series of inspection machine has seen constant adaptations and improvements, mirroring landmark developments in the pharmaceutical industry. In 2023, the well-established solution embarked on yet another refinement journey.

“We strive for an inspection portfolio that reflects current technological developments,” says Susumu Masuyama, product manager at Syntegon. “And we identified considerable potential for our AIM5 series of inspection machines for vials, syringes, cartridges, and ampoules.”. With its R&D and assembly in Japan, the AIM5 series still counts as an important part of Syntegon’s broad inspection portfolio and serves as one of its key solutions in terms of visual and container closed integrity (CCI) testing. Its recent modernizations include advancements in terms of a combination CCIT and visual attachments, shorter delivery times for standardized inspection configurations, as well as AI image processing capabilities.

CCIT for all requirements

Container closure integrity testing (CCIT) comprises several technologies, which Syntegon chose to integrate into its platform to meet market expectations. “The pre-filled syringes market experiences strong growth. High-voltage leak detection (HVLD) is the method of choice to ensure optimum CCIT for this demanding container type,” says Susumu Masuyama. The solution is built into the pre-spin turret without extending the machine’s footprint. The same holds true for the equally crucial oxygen measurement in vial headspaces: while the technology required stand-alone systems in the past, the AIM5 now comprises a state-of-the-art headspace measurement sensor in the starwheel.

The AIM5 series provides key technologies for visual and CCI testing

Standardization of vial inspection machine models to shorten delivery times

In terms of vials, standardized configuration models with set inspection items for major products (water-like liquids, lyophilized formulations and light suspensions) have been developed. The AIM5 series also offers the possibility to inspect different product characteristics in one platform.

With one size change part and a single recipe setting, a delivery time of 6-7 months only is feasible.

For syringe inspection machines, a modular design with a choice of either 2 or 3 inspection turrets has been introduced that can be tailored to the customers’ requirement of inspection items. If desired, the AIM5 line can also be offered in combination with a de- and a renester.

A unique feature

In terms of visual inspection, the AIM5 includes Static Division (SD) technology, a cornerstone of automated inspection developed by Eisai Machinery, now part of Syntegon. It derives its name from the ability to differentiate static from moving objects. Through the combination of visual inspection technologies with CCIT on the same platform, customers can tailor their processes to meet the inspection requirements of their products.

The Static Division (SD) technology can differentiate static from moving objects

Intelligent image processing

Among the countless benefits of Artificial Intelligence, pattern recognition stands out – and has rapidly proven its worth for image processing. Syntegon adopted the technology at an early stage, offering retrofit kits for existing inspection machinery, including previous versions of the AIM5. The latest version is now optionally available with AI software, and can be used alongside classical, rule-based image processing tools.