R&S IMAGER uses millimetre wave imaging to inspect in real time
With the new R&S IMAGER, Rohde & Schwarz is expanding its real-time millimetre wave inspection portfolio. The R&S IMAGER uses innovative imaging technology to penetrate materials with invisible millimetre waves, analyse the return signals using a sensor array and convert them into razor-sharp images that reveal any hidden structures or material defects.
The non-ionising radiation of the R&S IMAGER does not affect the efficacy of pharmaceutical substances in any way. Thus, the new system fills a long-standing gap in the camera-based or weight-based inspection of pharmaceutical packaging. Multi-layer secondary packaging, cardboard boxes and laminated seals are transparent to millimetre waves, allowing the sensor to detect syringes, needles and auto-injectors inside. The system generates a three-dimensional representation of each package at production speed, which ensures all components and their correct assembly can be fully inspected. By using artificial intelligence to evaluate the volumetric images, production lines can automatically detect missing or misaligned parts without affecting throughput. The applied millimetre waves eliminate any risk of radiation-related damage to sterile products, help ensure compliance with regulatory requirements and reduce costly recalls.
The penetration capabilities of the R&S IMAGER also offer logistics advantages. Weight scales and conventional surface inspections cannot confirm that the correct, high-quality product is inside sealed packaging, and X-ray methods raise both safety and regulatory concerns. The R&S IMAGER projects millimetre waves through plastics, cardboard and composite materials, producing an internal view that reveals missing parts, misplaced objects or damage. When integrated into a conveyor belt system, the R&S IMAGER provides a continuous stream of images that are analysed by AI algorithms to inspect the contents and detect anomalies in real time. This reduces the need for manual checks, improves inventory accuracy and ensures complete documentation of the entire supply chain for each shipment. The technology also promotes the use of more environmentally friendly packaging – even when manufacturers use more sustainable, but potentially opaque, materials, contents can still be monitored reliably.
The unit provides a non-invasive method for inspecting sealed cartons, multipacks and glass containers in the food and beverage sector. Millimetre waves easily penetrate standard packaging to reveal missing items, damaged products or sealing defects that would otherwise remain hidden. This makes it possible to detect even the smallest deviations, such as a loss of vacuum in glass bottles. Operators can implement strict safety and quality standards even with production lines running at full speed. Since the non-ionising radiation affects neither food quality nor employee health, the solution complies with all safety regulations.
The system’s architecture also means the scanner can be integrated into existing production control software, allowing engineers to expand inspection capabilities with no need for fundamental redesign of the manufacturing environment. The transition from surface-based inspection to volumetric millimetre wave imaging marks a quantum leap in quality assurance.
