With the R&S IMAGER, Rohde & Schwarz is introducing an imaging inspection system that inspects packaged products in real time using millimetre waves. The technology penetrates a wide range of packaging materials, operates without ionising radiation and generates three-dimensional images of the packaging’s contents. This enables the detection of hidden structures as well as potential material and assembly defects without opening the packaging or interrupting production processes.
The system is based on the analysis of reflected millimetre waves. A sensor array processes the signals and generates high-resolution 3D images that serve as digital representations of the products. These volumetric data sets can be integrated into automated, AI-supported quality assurance processes and enable continuous inspection directly on the production line.
Non-destructive testing in the pharmaceutical industry
Rohde & Schwarz sees a key area of application in pharmaceutical production. As millimetre waves are non-ionising, they do not affect either the efficacy or the quality of pharmaceutical products. At the same time, they can penetrate packaging materials such as cartons, multi-layer secondary packaging or laminated seals, allowing the contents to be visualised in three dimensions.
In this way, for example, syringes, auto-injectors or cannulas can be inspected inside sealed packaging. In addition to verifying the completeness of the packaging contents, their correct positioning can also be checked. In combination with AI-supported image analysis, missing or incorrectly assembled components can be automatically detected without affecting production throughput. At the same time, the process supports regulatory requirements for quality assurance and helps to identify production defects at an early stage.
Greater transparency in logistics and dispatch
Millimetre-wave technology also opens up new possibilities for logistics and dispatch processes. Whilst traditional visual inspections or weight checks only allow conclusions to be drawn about the condition of the packaging, the R&S IMAGER provides a view inside sealed packaging made of plastic, cardboard or composite materials.
Integrated into conveyor systems, the system continuously generates three-dimensional images of the packaging contents. AI algorithms analyse this data in real time and identify missing, misplaced or damaged products. This reduces the need for manual checks, enables picking errors to be detected more quickly and ensures that supply chains are fully documented.
Furthermore, the technology supports the use of sustainable packaging materials. Even if these are less visually transparent, reliable inspection of the contents remains possible.
Quality control for food and drink
In the food and drink sector, the R&S IMAGER enables non-destructive inspection of sealed packaging during the ongoing production process. Cartons, multipacks or glass containers can be checked for completeness, packaging defects or damaged products without opening the packaging.
According to the manufacturer, even subtle changes inside the packaging can be detected, such as leaks or vacuum loss in glass containers. This allows quality deviations to be identified during production, thereby reducing waste. As the process operates without ionising radiation, it is also suitable for sensitive food applications.
AI-supported image analysis expands quality control
A key advantage of the system lies in the combination of millimetre-wave imaging and automated data analysis. The 3D data sets generated can serve as digital twins of individual products and be integrated directly into AI-based inspection systems. This allows quality controls to be largely automated and production processes to be continuously monitored.
The open system architecture also facilitates integration into existing production and control systems. Companies can expand existing production lines to include volumetric inspection methods without having to fundamentally adapt their infrastructure.
New possibilities for industrial quality assurance
With the R&S IMAGER, Rohde & Schwarz is bringing millimetre-wave imaging to industrial inspection processes. The combination of non-destructive testing, three-dimensional imaging and AI-supported analysis opens up new possibilities for the quality control of packaged products. Particularly in regulated sectors such as the pharmaceutical industry, as well as in food production and logistics, the technology can help to detect defects at an early stage, automate processes and improve traceability within the supply chain.
