CASE
FULLY AUTOMATIC FILLING SYSTEM FOR HPLC CARTRIDGES
CHALLENGE
Bio-Rad RSL is a Belgian manufacturing and research unit within the Bio-Rad Clinical Diagnostics group. RSL specializes in the production of HPLC accessories used in diagnostic kits for applications such as diabetes monitoring. The production of resins and HPLC cartridges is central to its operations.
The production of these cartridges is based on the filtration of suspensions under high pressure.
Until recently, these cartridges were manually loaded, filled, and dispensed, and then automatically pressed in 15 stations operated by 6 operators. Bio-Rad RSL has entrusted IMA with the task of fully automating this production process.
SOLUTION
IMA has developed the following solution:
• The empty cartridges are manually placed on a conveyor belt, and the full cartridges are removed.
• A manipulator places empty cartridges into one of the seven filling stations, which fills the cartridges using a metering pump and then presses the filling into the cartridge.
• The filled cartridges are automatically removed from the pump station and returned to the feed conveyor
Due to the high operating pressure of 400 bar, the pump station is designed for high pressure and constructed of stainless steel. It also features a built-in automatic flushing cycle, complete with an end-of-day protocol, a startup module, and an ID scanner.
Mr. Chris Dewaele, general manager of Bio-Rad RSL, summarizes
:“Given the complexity of the project, the collaboration between IMA and Bio-Rad RSL went quite smoothly in terms of creativity and timeline. We are convinced that this will increase not only our productivity but also the quality of our products.”
SAVINGS
The automatic filling line is operated by a single operator and achieves the same production volume as the 4 to 5 operators in the manual process; as a result, BIORAD was able to increase not only productivity but also product quality.
PARTNER SPEAKS
Bio-Rad RSL is a Belgian manufacturing and research unit within the Bio-Rad Clinical Diagnostics group. RSL specializes in the production of HPLC accessories used in diagnostic kits, with a focus on the production of resins, HPLC columns, and cartridges. Dr. Chris Dewaele, general manager of Bio-Rad RSL, is happy to provide further explanation.
Bio-Rad RSL manufactures cartridges for measuring blood sugar levels in diabetes patients. These cartridges are produced under high pressure, during which they are filled with a unique liquid-granule suspension. “IMA automated the production of these cartridges as early as 2007,” says Chris Dewaele. “Before that, the application, filling, and dosing were done entirely by hand, after which they were automatically pressed in 20 stations, operated by 10 operators.” For Bio-Rad, the investment in a machine has not only led to a continuous reduction in production costs but also to a significant improvement in product quality compared to the previous, manual processes.
NEW PRODUCT REQUIREMENTS
In addition to an increase in capacity, new product requirements were established and improvements to 2D barcode identification needed to be implemented, so it was time for a new machine. “IMA was responsible for the complete mechanical design—using state-of-the-art technology—the electrical design, and the development of the specific machine software. Furthermore, the new machine was equipped with a new data-logging system,” explains Chris Dewaele.
SMOOTH COLLABORATION
Given the complexity of the project, the collaboration between IMA and Bio-Rad RSL went extremely well—both in terms of creativity and the timeline. “We’re convinced that using this machine will not only boost our productivity but also improve the quality of our products,” says Chris Dewaele with a smile.
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