DIR Technologies has developed an infrared thermal imaging system called the Induction Integrity Verification System (I2VS) that allows for 100% real-time inspection of induction heat seals on pharmaceutical packaging. The technology scans bottle caps and detects defects in seals, providing pass/fail results for every unit. Major pharmaceutical firms are adopting the system to replace manual sampling methods. DIR is now launching a new I2VS Lite model to expand into food and consumer goods markets. The system promises to increase quality assurance and reduce costs from defects.

1. advanced packaging
technology world
The journal of advanced packaging technology
volume 3 issue 15 18 August 2015 Smithers PIr a
Special reports
Trakrap takes cold wrapping into new markets
Schreiner MediPharma labels respond to new regulatory
demands
New generation of PE antioxidants given green light by
FDA
DIR looks to bring 100% real-time infrared inspection to
packaging industry
advanced packaging technology world provides authoritative
analysis of technology and market trends in active and intelligent,
flexible, smart, and interactive packaging.

2. DIR looks to bring 100%
real-time infrared inspection to
packaging industry
A high-tech solution for non-invasive
checking of induction heat seals is now
coming to market
8

3. Volume 3 Issue 15
9
n Israel, DIR Technologies is reporting
success in repurposing cutting-edge
military thermal imaging technology for
the packaging industry.
Its Induction Integrity Verification System (I2VS) allows
for the inline verification of the foil induction seals
on every unit of a run of bottles. This is now being
adopted by major firms in the pharmaceuticals
segment – like Pfizer – and was recently acknowledged
with a Best Innovation Award at the process industry
trade show Achema 2015, held in Frankfurt on 15-19
June.
Commenting on this Fabian Schapiro, DIR vice
president of marketing and sales, says: ‘This award
is another symbol of the growing recognition of our
technology and the benefit of our inspection solutions
for pharmaceutical manufacturers around the world.
‘DIR has gone beyond innovation with a solution that is truly unique and that we believe will eventually become the new
industry standard.’
Advanced Packaging Technology World spoke exclusively to Schapiro. He explained the specialist technology underpinning
the I2VS and revealed the company is planning to launch a new model to expand into higher volume packaging markets.
Military pedigree
The DIR verification platform is based on thermal imaging that uses emissions in the infrared section of the spectrum
to examine whether a bottle is properly sealed. This technology is well understood around the world, and has made the
transition from use in military equipment, like night vision goggles, into commercial devices like smartphones.
Israel’s long history of conflict means its defence sector – and infrared imaging equipment – is one of the most technically
advanced in the world. It is this expertise that DIR has been able to leverage to give a unique solution for sealing
verification. The company was spun off from military systems developer SemiConductor Devices (SCD) in 2009, and
continues to work in partnership with local defence sector companies, Rafael and Elbit Systems.
Schapiro says: ‘DIR is the first company in the world to leverage highly sensitive thermal imaging technology for the
packaging industry and, in particular, for pharmaceutical primary packagers. Combined with sophisticated analysis
algorithms, the company has developed an inspection method that did not previously exist, and promises to change the
status quo for quality and process control. The standard method today for sealing integrity inspection is manual sampling,
whereas the I2VS promises 100% passive, hands-off, non-destructive, in-line testing of every single bottle.’
Sensitivity
He continues: ‘The sensitive technology utilised by DIR enables the I2VS to inspect sealing integrity – seeing through
opaque bottle caps as if they are not there. Although other forms of infrared have been used in the pharmaceutical
industry before, the thermal imaging technology that DIR uses is the only one sensitive enough to achieve these results.
‘The I2VS is calibrated to various pharmaceutical packaging lines, depending on the types of cap and bottles in use.
DIR’s analysis software translates the thermal image data in comprehensive, operator-friendly information, providing
an immediate accept or reject for every bottle. In addition, the system provides an indication of what the likely fault is,
enabling operators to amend issues in real time, and also avoid problems pre-emptively.’
I
The sensitive technology utilised by DIR enables the I2VS to inspect sealing integrity – seeing through opaque
bottle caps as if they are not there
‘ ’ advanced packaging
technology world
Infrared signatures can reveal production faults – like an
incompletely sealed foil top under a plastic cap (centre)
Source: DIR Technologies

4. 10
Full batch verification
DIR introduced its first equipment 2013 and this has
since been undergoing extensive beta testing with
a number of pharmaceutical companies across the
world.
The Haifa-based equipment builder has deployed
the same technology for in-line verification of the
sealing of sachet packaging – again for use initially
in the pharmaceuticals segment – with its SFM
module (see inset).
DIR’s cameras can scan every unit in a production
run, with no detrimental effect on throughput speed.
It reports the fastest current installation of I2VS
operates at a speed of 400 bottles per minute. For
firms operating in high-value, life-critical industries
like pharmaceuticals this offers a compelling
alternative to current verification techniques based on
periodic, destructive sampling, and human inspection.
Schapiro adds: ‘We are initiating a big change in the packaging industry and it is forward-thinking pharmaceutical
companies that are implementing it. It is not easy to implement a new technology in an industry that is so highly regulated
and thus very conservative. It is the change-makers – companies that are innovative in their own right – who are leading
the way. They are doing this for one simple reason: the benefits are clear. Ultimate quality assurance, detecting issues,
and amending them in real time is very valuable. Preventing them from occurring in the first place can be even more
significant. Preventing the added labour costs, work-backs, production downtime and material waste associated with
handling defects is important. When you check 100% in real time, it is a big change.’
I2VS Lite
The need for an alternative to sampling verification procedures is a trend across the packaging industry – and is one
equipment innovators are looking to meet with remote scanning technologies. In Sweden Gasporax is commercialising
tuneable diode laser absorption spectroscopy (TDLAS) than can detect faults in modified atmosphere packages (MAP),
inspecting all packs on high-speed lines (see Advanced Packaging Technology World 2.17, 15 September 2014).
Having proven its technology with extensive beta-tests in the demanding segment of pharmaceutical packaging, DIR is
now poised to enter more mainstream markets. At Pack Expo 2015 in Las Vegas on 28-30 September it will showcase a new
model, the I2VS Lite.
Schapiro says: ‘The I2VS Lite a simpler version of the I2VS
optimised for non-pharmaceutical packaging sectors – in
segments like food and beverages, cosmetics, and cleaning
products. It has the same core technology and capabilities in
detection and analytics, but does not have all the elements
built to comply with the stringent pharmaceutical packaging
manufacturing regulations.’
The proposition for converter will be the same – increased
quality assurance and the ability to take remedial action
immediately a problem is detected, cutting wastage and
costs. At the same show, DIR is also planning to debut a heat
sealing inspection system called DIR Eye, fitted to a Shemesh
Automation SealPro machine. The DIR Eye is looking to tap
new markets in the cosmetics and food segments.
advanced packaging
technology worldVolume 3 Issue 15
We are initiating a big change in the packaging industry and it is forward-thinking pharmaceutical companies
that are implementing it – When you check 100% in real time, it is a big change
‘ ’
High-end infrared platforms like I2VS can be calibrated to scan
through a range of plastic tops fitted over foil container seals
Source: Enercron
Launched in March 2015, DIR Technologies’s Sachet Full
Monitoring (SFM) inspection device adapts the infrared scanning
of the I2VS to sachet packaging.The non-invasive technique allows
for the monitoring of all packages on a sachet roll.
The SFM is being sold as a module for integration into existing
lines for converters and fillers operating in the pharmaceutical
and personal care segments.
It is also being offered as a component of the sachet machinery
manufactured by German equipment builder MediSeal. In this
application the DIR system operates at up to 100 cycles per
minute and can see inside aluminium, polyethylene, polyethylene
terephthalate (PET), paper, and Tyvek laminates.
Sachet inspection

5. Future markets
The same technology could in future be adapted away from induction seals to work on other types of pack sealing. It could
also have applications in checking for foreign objects or fill levels inside opaque plastic containers – providing a more
sensitive alternative to weighing mechanisms, especially for less heavy goods.
In April 2015, DIR announced the signing of a five-year joint development accord with Pfizer to further evolve its technology,
building on positive response of trails of the I2VS. This will include a project to produce a ‘new system intended to perform
100% in-line inspection of tablets and capsules.’
This public backing from one of the biggest names in the pharmaceutical industry, which has already road-tested the
system, should help convince the mainstream packaging industry of the usefulness of I2VS platform, once the new
simplified model goes on sale.
The trickle down of technology from advanced military systems can offer demonstrable time and cost savings for checking
seals, and allow a move away from invasive product sampling techniques. The less stringent qualification code for new
packaging equipment in these segments means its penetration could be rapid, provided the DIR platform can match the
typically quicker throughput speeds on converting lines for fast-moving consumer goods ■
11
advanced packaging
technology worldVolume 3 Issue 15
provides authoritative analysis of technology
and market trends in active and intelligent,
flexible, smart, and interactive packaging.
Smithers Pira is a leading consultancy
business with major publishing and
conference activities, serving retail supply
chain technologies.
© Smithers Pira 2015
ISSN 2049-5862
Published by
Smithers Pira
Cleeve Road, Leatherhead
Surrey KT22 7RU, UK
T +44(0)1372 802080
F +44(0)1372 802079
E publications@smitherspira.com
www.smitherspira.com
Editor
John Nelson
Head of Digital Publishing
Dan Rogers
advanced packaging technology world