Project recently completed at Westwards Microbiology Laboratory demonstrates the benefits of automation and mechanisation for increased productivity, reduced errors, and improved traceability
Automation and mechanisation are key requirements in high throughput environments such as analytical laboratories.
A recent project completed at Westwards Microbiology Laboratory by Kiestra Lab Automation (Netherlands) and Autoscribe UK demonstrates how such projects can lead to increased productivity, reduced human errors, and improved tracking and traceability.
Westward's microbiology laboratory processes hundreds of samples each day for microbiological analyses such as total viable count, yeast and mould, coli, E coli, entero, salmonella, etc.
Thus there was a requirement for a system which would not only automate the actual testing process but also track and trace the samples and associated results.
The key to this real-time automation is real time barcode labelling of all sample carriers (such as bags, tubes, dishes, bottles) provided by Kiestra's BarcodA system.
This is used in conjunction with Autoscribe's Matrix Lims system (a fully configurable Lims with tracking functionality).
Real time bar coding dramatically reduces the transcription error rates to only one in 36 trillion characters.
Compare this to manual coding/reading/writing where there can be an at least one error in 300 characters, and the necessity for bar coding becomes clear.
BarcodA is a system that automatically places an optical barcode on all tubes, bottles and petri dishes.
This code contains all important information like composition, sell-by date etc.
With this barcode, every sample carrier is unique and recorded meaning full traceability for the laboratory.
Samples are also provided with a barcode which is generated by Autoscribe's Matrix Lims laboratory information management system.
Automated sample preparation and dilution with SynergA and TraceA.
The first step of each sample's preparation is dilution.
This is performed by Kiestra's gravimetric dilutor, the SynergA (described as the fastest dilution system available).
This gravimetric dilutor is connected to a PC via TraceA software which allows full traceability of all dilution operations.
In fully automatic mode, the sample barcode includes information about the type of dilution required (sample information including the weight of sample, diluent, dilution factor is also recorded giving improved accuracy).
When the sample barcode is scanned, the system automatically checks to see if the starting weight is within the predefined limits, selects the bottle of media to be used (if several are connected at the same time), makes the dilution and checks if the accuracy is correct.
At the workstation the TraceA software package makes sure that all relevant data is stored automatically (date, time, analyst ID, sample ID, weight of sample, media batch number, weight added, and media).
The data are then automatically exported to Matrix Lims.
The next stage is testing.
Every sample tested requires a petri dish (apart from pathogen samples that are tested in a separate laboratory).
Barcode labelling of each dish is an automated process performed by Kiestra's BarcodA system at a speed of 1000 dishes per hour.
Sample barcodes are scanned at the pipetting bench with a barcode scanner.
Autoscribe Matrix Lims then sends the tests associated with the particular sample to BarcodA so that the petri dishes can be labelled with a barcode specific for each test.
The technician then instantly receives the right set of test plates per sample.
Automated agar plate preparation with AgarrA.
After pipetting the sample into the petri dishes and assignment of the associated tests, the Kiestra AgarrA module comes into action.
AgarrA is used for automatic agar pouring, mixing, solidifying and stacking.
This system automatically scans the barcode on each dish and pours the plate with the correct molten media for the test, after which mixing, solidifying, and stacking takes place.
AgarrA enables users to save 30% of agar costs each day, thanks to the exact dosing system.
Matrix Lims receives all the relevant data from BarcodA and AgarrA, in order to keep track of the whole history per sample to an individual dish level.
During the whole process, an automatic check is also made at each step to determine if all required samples have passed the required step before proceeding to the next step.
This ensures that all the necessary steps in the process are completed.
Based upon this principle, Westward Labs can generate complete daily audit trails for every sample.
This provides an excellent management reporting tool for Westward Increased efficiency, throughput and traceability.
Kiestra's automation concept is: it's the sample that moves.
Westward is able to process more samples in a shorter time window by adopting this concept, creating a substantial increase in efficiency and throughput.
With real time interaction with Autoscribe's Matrix Lims, Westward is sure that all samples are processed as they should be and are fully audit trailed to meet the increasing demands of their customers and Ukas.
