Why Pharma Packaging Needs Roll Label Counting Machines?

In the pharmaceutical industry, packaging is not just about presentation, it is a critical part of compliance and patient safety. Every label on a vial, ampoule, or bottle carries essential information such as dosage, batch details, and traceability codes. Even a small error in label counting can disrupt supply chains, cause compliance violations, or lead to costly recalls. Under strict Good Manufacturing Practice (GMP) guidelines, pharma companies must ensure that every label received, used, and dispensed is accurately tracked.This is where Roll Label Counting Machines play a vital role. By automating the label counting process, these machines eliminate human error, ensure compliance, and provide accurate documentation, helping pharma manufacturers safeguard both efficiency and regulatory integrity.

Introduction to Roll Label Counting in Pharma

Accura’s Roll Label Counting Machine is designed to count labels with precision, while also offering winding and rewinding.

The absence of automated counting systems introduces major risks:

• Manual inspection in label counting –Manual inspection in roll label counting is impossible and weight counting can be inaccurate.
• Delays and inefficiencies – manual recounting slows down production and increases labor costs.
• Compliance risks due to mislabelling – errors in label application may result in warnings, penalties, or product recalls in regulated markets.

Benefits of Roll Label Counting Machines

Presetting  for Batch Accuracy

In practice, these machines ensure packaging departments can handle large rolls efficiently while dispensing only the required number of labels for a given batch.

For example, if a roll contains 5,000 labels but the line requires only 1,000, the machine can be preset to stop automatically once 1,000 labels are dispensed.

Traceability in Label Counting

For pharma packaging where these counts and processes are to be recorded, Accura offers a model of the machine–the HMI Plus, that creates printable records of the name of company, name of product, batch number, quantity received and counted number, date and time, operator. This can be further filed for audits and inspections for compliance.

Accuracy in Counting Labels

Modern machines use specialized sensors that detect labels through gaps, black marks, or straight lines. They can even detect missing labels and stop automatically, ensuring no defective roll passes forward.

Speed & Efficiency for Pharma Packaging

High-speed counting with consistent accuracy keeps production lines moving efficiently. Large rolls can be managed without bottlenecks, improving overall throughput.

Reducing Human Errors and Material Waste

By replacing manual counting, machines significantly reduce dependency on human intervention, minimizing wastage and avoiding costly rejections.

Flexibility with various label types

Various sensors are available to handle different types of labels, whether plastic on plastic web, paper, or other substrates.

Winding & Rewinding with Label Counting Machines

These machines also provide winding and rewinding functionality, with the option to reverse the direction if required, allowing the roll to be returned to its original position after counting.

Role of Label Inspection Systems in Quality Assurance

While counting ensures quantity, Label Inspection Systems ensure quality. These systems verify the correctness of barcodes, serialization codes, and printed information. For pharmaceutical packaging, where every label carries unique identifiers, inspection systems provide an essential safeguard against:

• Misprints or missing data
• Incorrect barcodes
• Non-compliance with serialization regulations

Choosing the Right Roll Label Counting Machine

When selecting equipment, pharma companies should evaluate:

• Presetting capability for batch-based dispensing
• 21 CFR Part 11 compliance for secure, audit-ready documentation
• Advanced sensor technology to accommodate varied label materials and markings
• Automated reporting, for example, Accura Pharmaquip’s HMI+ model generates printable reports capturing company name, product name, batch number, label quantity, operator ID, and date/time.

Accura Pharmaquip offers a streamlined product suite for label accountability, including:

• Label Counting Machine STANDARD – capable of counting up to 1,500 labels (or 100 meters) per minute, complete with preset and total count functionality in both wound and rewound directions.
• HMI PLUS – featuring high-speed label counting (1,500–2,000 labels per minute), coupled with a 7-inch touchscreen (HMI) for spool selection, motor control, and a print-out facility for records.
• LISA – a combined counting and inspection system that not only counts efficiently but also inspects entire labels, including barcode, pharmacode, and 2D code verification. It runs on a powerful IPC with a Core i3 equivalent processor,  SCADA software, and supports report generation via USB prints; it is cGMP-compliant and supports 21 CFR Part 11 if needed

As regulatory standards tighten and traceability becomes more critical, pharmaceutical manufacturers cannot afford to rely on manual or inaccurate label counting methods. Automated roll label counting and inspection systems not only guarantee accuracy but also provide audit-ready documentation that meets global compliance norms like cGMP and 21 CFR Part 11.

Accura Pharmaquip’s range of solutions, including the STANDARD, HMI PLUS, and LISA models, are already trusted by leading pharma companies such as Cipla, Sun Pharma, Lupin, and GSK. These systems combine speed, precision, and compliance to streamline label accountability across packaging lines.

If your pharma business is looking to strengthen compliance while improving efficiency, explore Accura Pharmaquip’s Roll Label Counting Machines, engineered for accuracy, reliability, and future-ready pharma packaging.