Millimeter waves make hidden structures visible

The 'R&S IMAGER' uses millimeter-wave imaging technology. Invisible millimeter waves penetrate the packaging materials, while the return signals are detected by a sensor array and processed into high-resolution images. This makes it possible to visualize hidden structures and material defects.

Quality Control for Pharmaceutical Packaging

In the pharmaceutical industry, the system is intended to fill a gap that camera- or weight-based inspection methods have so far left unaddressed. Since the radiation used is non-ionizing, the manufacturer states that the efficacy of pharmaceutical substances is not compromised. At the same time, multi-layer secondary packaging, cardboard boxes, and laminated seals are permeable to millimeter waves, allowing syringes, needles, or autoinjectors inside to be detected.

The system generates three-dimensional representations of each individual package at production speed, thereby enabling a complete inspection of all components and their correct assembly. Based on the volumetric image data, AI algorithms can automatically detect missing or misaligned parts without affecting the production line’s throughput. According to the manufacturer, eliminating the use of ionizing radiation also eliminates the risk of radiation-related damage to sterile products. At the same time, the system is designed to help meet regulatory requirements and reduce the likelihood of costly product recalls.

Applications in Logistics

Rohde & Schwarz also sees advantages for millimeter-wave imaging in logistics. While checkweighing and conventional surface inspections cannot reliably confirm whether the correct, high-quality product is inside a sealed package, the device projects millimeter waves through plastics, cardboard, and composite materials to generate an internal view of the package. This makes it possible to detect missing items, misplaced objects, or damage.

Integrated into a conveyor belt system, the device provides a continuous stream of images that are analyzed by AI algorithms to inspect contents and detect anomalies in real time. This is intended to reduce the need for manual inspections, increase inventory accuracy, and enable seamless documentation throughout the supply chain. At the same time, the technology supports the use of sustainable packaging materials, the contents of which can be reliably inspected despite potentially opaque materials.

Applications in the Food and Beverage Industry

The manufacturer also sees potential applications in the food and beverage sector. The system enables non-invasive monitoring of sealed cartons, multipacks, and glass containers. Since millimeter waves penetrate standard packaging, the system can detect missing items, damaged products, or sealing defects that would remain hidden during a surface-only inspection. According to the company, even the smallest deviations—such as a loss of vacuum in glass bottles—can be identified.

This is intended to ensure that safety and quality standards can be maintained even at high production speeds. Since the non-ionizing radiation used does not affect either food quality or employee health, the solution complies with applicable safety regulations, according to the manufacturer. Early defect detection is also intended to reduce waste, extend shelf life, and strengthen the brand image.

Integration into existing production lines

According to Rohde & Schwarz, the system architecture also supports integration into existing production control systems. This is intended to enable companies to expand their inspection capabilities without having to fundamentally redesign their manufacturing environment.

The transition from surface-based inspection to volumetric millimeter-wave imaging marks a significant advance in quality assurance. Against the backdrop of increasingly complex supply chains and rising regulatory requirements, the ability to quickly inspect every single product unit could become a decisive competitive advantage.