What needed solving
Manual tray counting took time and could miss or double-count closely packed vials. Different vial sizes and cap colours also changed their appearance under the camera.
How Qualitas solved it
Qualitas installed an overhead imaging setup with uniform illumination and trained a vial-detection model in EagleEye. The deployed model identifies visible vials and displays the tray count to the operator.
The acquisition setup
The camera looks down onto the tray. Custom lighting provides an even view across the vial caps, making consistent image capture the starting point for counting.
The count made visible
- Capture the loaded tray under the overhead camera.
- Detect the visible vials with the trained EagleEye model.
- Display the count and inspection result for the operator’s reconciliation check.
Adapting to vial variation
Representative vial images were labelled and used to train the model. Additional examples improved recognition of unfamiliar variants.
The count check supports loading and dispatch workflows where the number of vials must reconcile with the tray record.
Share tray dimensions, vial sizes, cap colours and the time available for counting. We can evaluate the lighting, camera coverage and count verification on representative trays.
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