An export-oriented multinational formulation company running 400 vials per minute experienced a 2.4% reject rate during automatic optical inspection (AOI) due to scuff marks produced by OEM change parts.
1. Contact Friction Profiling
Standard injection-molded pockets developed microscopic ridges over extended production runs. As vials spun into the rotary cap sealing turret, tangential friction generated fine surface scuffs.
2. CNC 5-Axis Inlaid Pocket Fabrication
Vedax manufactured custom virgin Delrin starwheels with inset virgin PTFE low-friction wear pads. Pocket radii were contoured to match the exact vial perimeter curvature.
3. Optical Inspection Zero-Defect Outcome
Upon implementation, AOI optical reject rates plummeted from 2.4% to less than 0.05%, saving the customer over $180,000 annually in scrapped packaging materials and lost fill volume.
Implementation Recommendations
- Validate pocket contours against container drawing tolerance band.
- Execute 100% CMM coordinate verification prior to shipment.
- Provide standardized tool-less quick changeover locking mechanisms.
Have a Technical Requirement?
Consult directly with our tooling engineers to troubleshoot container breakage, fill accuracy, or custom machine format conversions.
Request Technical Consultation +91 88660 36337