Zero-Defect Quality Control: Six-Stage Verification Process Based on the Keyence AI Vision System
Janytree challenges zero defect rates through a multi-stage quality verification process that combines the precision of advanced automated machinery with the responsibility of skilled inspectors.
Six-Stage Zero-Defect Vial Manufacturing Process
Janytree’s vial-dedicated automated lines minimize process changeover time and maximize production yield. They can respond flexibly from early-stage startup volumes to large-scale orders from major brands.
STEP 1
Pharmaceutical-Grade Ultra-Pure Water System from the Foundation
Bulk Manufactured with Multiple Layers of Safety
- WFI-level water quality: Bulk is manufactured using sterile, non-pyrogenic ultra-pure water that goes beyond simple purified water.
- Two-stage bulk filtration: Bulk manufactured with ultra-pure water passes once more through sterilizing and endotoxin filters before filling, blocking contamination at the manufacturing stage.
- Fully sealed storage: Completed bulk is stored in sterile single-use bags through sterilized transfer lines, completely isolated from external air.
STEP 2
Dual Foreign-Substance Removal & Precision Filling
Washed Vials & Deep-Nozzle Suction
- Sterilization and drying: Only safe vials that have passed an 800°C high-temperature drying and sterilization process after washing are used.
- Dual foreign-substance removal: Immediately before filling, Deep-Nozzle Suction once again removes foreign substances inside the container to prevent contamination at the source.
STEP 3
E-beam Sterilization & Ionizer Air Cleaning
Sterilized Rubber Stoppers & Ionizer Air
- Safe sealed filling: Only E-beam sterilized rubber stoppers are used, and just before capping, static electricity and foreign substances are removed with Ionizer Air before automatic capping to achieve complete sealing.
STEP 4
First AI Vision Inspection: Contents and Capping
360-Degree Vision Inspection for Foreign Substances
- 360-degree inversion inspection: After filling and capping, vials are flipped 180 degrees through a twister conveyor to thoroughly detect foreign substances at the bottom of the vial.
- Keyence vision system: Three high-resolution cameras from Keyence automatically track, sort, and remove products with foreign substances, insufficient fill volume, or capping defects in real time.
STEP 5
Second AI Vision Inspection: Label and Coding
Smart Marking & Secondary Vision Inspection
- Top-cap coding: Expiration date and LOT number are automatically marked on the vial cap to improve readability and management efficiency.
- High-precision labeler: An automatic vial labeler creates a clean appearance without lifting or gaps.
- Secondary precision appearance inspection: The vision system checks label attachment status and missing coding to pursue a 0% defect rate before shipment.
STEP 6
0.01 g Weight Sorting + Final Visual Double-Check
Automatic Weight Sorting & Visual Inspection
- Ultra-precision weight check: The automatic weight sorter checks content weight in 0.01 g units and automatically sorts and removes underfilled products.
- Double Check: Immediately before packaging, trained inspectors shake and visually inspect each vial. The final guarantee is completed by the 99.9% precision of machines and human responsibility.
- Final QC: Packaged products are ready for shipment only after testing, inspection, and final approval by professional quality inspectors.
Two Automated Lines Dedicated to Vials
Able to respond quickly and flexibly to the needs of the high-performance ampoule and serum market.
Compact Vial
Automated Line 01
- Vial size: 22ø x 33 mm (H)
- Filling range: 3 ml to 5 ml
- Filling unit: 0.1 ml
- Daily production capacity: 10,000 to 18,000 vials
Standard Vial
Automated Line 02
- Vial size: 22ø x 52.5 mm (H)
- Filling range: 8 ml to 10 ml
- Filling unit: 0.1 ml
- Daily production capacity: 10,000 to 18,000 vials
Quality & Smart Factory
Four standards behind every batch
01
70% of Cosmetics Is Water
Five-stage ultra-pure water system
Read more02
03AI & Human Responsibility
AI vision plus full visual inspection
You are hereSmart Factory
MES recipe integrity and traceability
Read more04Global Standards
ISO 22716 and twelve export markets
Read more