Redefining Visual Inspection in Parenteral Packaging

For decades, visual inspection of parenteral packaging has relied on rigid, rules-based camera systems—often difficult to program, slow to adapt, and costly to maintain. These limitations have left manufacturers struggling with inefficiencies, missed defects, and unnecessary expenses. Through our partnership with Boon Logic, Genesis Packaging Technologies is delivering a breakthrough in automated visual inspection: Advisum™, powered by AI-driven unsupervised machine learning. With this new platform, manufacturers can dramatically improve defect detection, streamline validation, and realize rapid ROI—all while reinforcing Genesis’ 75-year legacy of leadership in parenteral packaging innovation.

A Smarter Path for Container Closure Integrity

Vial capping machines in today’s industry frequently depend on rules-based camera systems to perform inspections. While these systems have served as the standard, they require significant manual programming for each defect type. Developing inspection “recipes” often means engaging OEMs or vision experts, consuming valuable time and resources. On top of that, software and hardware changes can quickly render these systems outdated, limiting adaptability to evolving production requirements.

The result? Inefficiencies, increased risk of missed defects, higher false reject rates, and added costs tied to rework or recalls. It’s a reactive approach to inspection—when the industry needs something more proactive, flexible, and cost-effective.

Introducing Advisum – Powered by Boon Logic AVIS

Genesis has long been a pioneer in the science of parenteral packaging and container closure integrity. Now, through our partnership with Boon Logic, we bring forward a transformative solution: Advisum, the Genesis visual inspection platform enhanced with Boon Logic’s AI-driven AVIS software.

Built on unsupervised machine learning, this system is designed for flexibility and ease of deployment:

• Retrofit Compatibility – Advisum can be added to cappers already equipped with rules-based camera systems or integrated as a stand-alone station. It can even be applied to semi-automated inspection booths for final inspection.
• Simple Validation – Unlike rules-based systems requiring defect libraries, Advisum can be trained quickly using only good product, making qualification straightforward.
• Rapid Deployment – With training times measured in minutes, the system reduces setup complexity while delivering results faster than traditional approaches.

Technical Insights

Traditional vision systems depend on defect libraries and rules-based analytics. By contrast, AVIS leverages unsupervised machine learning to detect anomalies and hidden patterns without pre-programming failure modes.

• 1,000× Faster Model Creation – AVIS builds models in minutes or hours rather than months.
• Defect Detection at Scale – Optimized for pre- and post-cap operations, it catches the full spectrum of common defects.
• Lower False Reject Rates – By modeling “normal” operation, the system avoids misclassifying acceptable product.

Testing conducted by Genesis Packaging Technologies and Boon Logic demonstrated that Advisum AI reliably detects defects on capping lines. In one case study involving a vial capping line, Advisum AI identified over 90% of defects while maintaining a false reject rate below 1%. It effectively detected issues such as crooked caps and missing stoppers, while significantly reducing false rejections, which previously led to production delays and increased costs.

Proactive Inspection for Modern Manufacturing

By introducing Advisum, Genesis Packaging Technologies and Boon Logic are changing the way manufacturers safeguard product quality. Defects are identified earlier, enabling real-time corrective action at the capping stage. This proactive approach reduces waste, prevents costly rework, and minimizes the risk of defective products reaching distribution.

More than just an inspection tool, Advisum represents a new standard for operational efficiency and product integrity in pharmaceutical manufacturing—continuing Genesis’ tradition of driving innovation in parenteral packaging.