Inline Pharmaceutical Serialization System

Overview

The Inline Serialization System is designed to integrate real-time code verification directly into existing pharmaceutical packaging and labeling lines.
Unlike offline or standalone units, this configuration eliminates the need for a dedicated printing module — focusing purely on vision-based inspection and data validation during live production.

From cartoning machines to bottle labeling stations, the inline system ensures every serialized item is captured, verified, and linked to its parent aggregation level without interrupting throughput.

System Architecture

At the heart of the system lies a dedicated control and vision cabinet, developed under my direction, containing all electrical, automation, and communication modules.
The printing stage is omitted; instead, high-speed industrial vision cameras read DataMatrix codes already printed in previous steps (either by the offline carton system or roll-rewinder label printer).

Each cabinet typically includes:

• Industrial PC (IPC) with serialization software and database integration

• PLC-based control logic using components from FATEK, Schneider, and Omron

• Custom HMI interface for line operators and supervisors

• Secure communication to upper-level Track & Trace servers

Applications

• Cartoning Lines: Reads and verifies codes on secondary packaging immediately after carton closure.

• Bottle Labeling Lines: Ensures every serialized label applied to bottles matches the parent batch.

• Rework & Aggregation Points: Captures serialization data where additional verification is required.

This modular design allows flexible installation on any production line — minimizing footprint and wiring complexity while maintaining full compliance with GS1 and IFDA traceability standards.

Electrical & Control Design

I personally developed the electrical schematics and control architecture using EPLAN, optimizing for industrial reliability and ease of maintenance.

The system supports:

• Real-time synchronization between PLC and vision software

• Integrated alarm and reject control

• Ethernet and Modbus communication for factory-level data connectivity

My Role & Vision

As the lead electrical designer and integrator, I designed, assembled, and commissioned multiple inline serialization systems across different production environments.
My focus has been on stable communication, operator-friendly diagnostics, and scalable integration with higher-level Track & Trace networks.