A need for speed

Rapid microbial methods can reduce laboratory waste and increase sustainability as well as make a significant contribution to operational savings says Jenny Woolway

Lean manufacturing is not a new concept, but by extending its core principle – of reducing or eliminating steps that do not add value – one can realise additional benefits in the quality department. Rapid microbial detection systems, for example, contribute to a leaner manufacturing process by empowering the laboratory to significantly reduce the idle time of awaiting test results, thus contributing time and cost savings to operations. At the same time, today’s efficient rapid detection systems increase sustainability in the laboratory.

The laboratory’s function is about safety first and foremost to ensure the company’s products are free of contamination. This serious attention to safety testing often means a serious amount of waste is produced and disposed of daily, not to mention the energy and water consumed in the process. Therefore, how can a laboratory move towards a more sustainable existence?

Efforts to be “greener” have already been adopted by many companies with solar panels, motion-detecting lights, energy monitoring and recyclable packaging measures to reduce a company’s footprint. Until now though, the laboratory is one area that has yet to see much improvement.

[caption id="attachment_34760" align="alignright" width="200" caption="Traditional microbial testing vs rapid detection method, which delivers definitive test results 80% faster, in addition to environmental benefits"][/caption]

Traditional microbial testing methods frequently require mixing batches of specialised media used to set up samples for observation. Numerous plates and jars of media and product are disposed of daily as both solid and liquid waste, sometimes hazardous. Water is used to prepare media and, along with electricity, to run the autoclave.

Progressive companies are already using rapid microbial methods to release products to market faster. These companies are benefiting, not only from reducing risk but also in terms of environmental value.

Rapid microbial methods can reduce the amount of material that is generated and then disposed of compared to traditional methods. Less waste to recycle or dispose of can be a big saving. Often a specialised medium is prepared for each standard organism type, as well as product- and site-specific organisms, for various product samples undergoing traditional test methods. Yet a rapid method requiring only a single broth enrichment can be used to screen for all microorganisms, including bacteria, yeast and mould. A company can quantify their savings using a rapid method with an environmental impact assessment, which helps companies evaluate their expected reductions in solid and liquid waste, as well as savings from reduced water and energy consumption.

By significantly reducing the amount of media, which has to be made on a daily basis, and the number of plates or jars set up, a rapid method in the laboratory can benefit by huge reductions in non-recyclable waste, caretaker and maintenance costs, disposal and landfill fees and autoclave use, which also reduces water and energy use.

A financial impact assessment, a companion tool, can also be used to project additional financial savings from implementing a rapid microbial detection method. This enables companies to estimate the value of adopting a rapid detection system using readily available company data.

[caption id="attachment_34761" align="alignleft" width="200" caption="An environmental impact test is used to identify 'green savings' from implementing a rapid detection system"][/caption]

When products are expected to be free of contamination, as is the norm with most consumer home and beauty products, pharmaceuticals and aseptically packaged food and beverages, then a rapid test for contamination that can confirm its absence or presence is an efficient tool in a company’s ability to release products to market faster.

When no contamination is detected, product can be released to market quickly. Only for the small percentage of cases when contamination is detected do the samples need to undergo a full battery of tests to identify and quantify the microorganism present. Running this more extensive testing on the few potentially contaminated samples — instead of on 100% of the testable samples — saves laboratory setup time and reduces the amount of lab waste generated on a daily basis.

The operational efficiencies of a rapid detection system have been well established; major global manufacturing companies have been using the method for decades. Faster product release testing contributes to company profitability by providing the following quantifiable benefits:

• Reduces working capital requirements – By shortening product hold times, rapid detection methods decrease investment in product held in quarantined inventory at any given time, thereby freeing up working capital. Also, because it takes fewer days to replenish the same amount of product, the shortened cycle time reduces safety stock requirements and its associated working capital investment.

• Improves operational efficiencies – Shorter cycle times create a leaner, more responsive manufacturing operation, which improves a company’s financial metrics – including return on invested capital and inventory turns.

• Shortens the cash cycle – With rapid detection methods, finished goods are released to market faster so companies can invoice faster and have more selling days for their products, leading to an accelerated revenue cycle.

• Swifter decision-making – A rapid detection system provides actionable information that allows product to move forward quickly. When contamination is detected, that batch can be isolated and attention focused on remediation and further process improvement.

As significant as it is to take days out of the production cycle, the benefits of rapid detection more than double if there is a contamination. The sooner a problem is identified, the faster the manufacturing line can be stopped, corrective action implemented, and production—and testing—of a replacement batch completed. This quicker response time minimises the risk of customer service interruptions or recalls, saving money at the same time as protecting the company’s reputation.

[caption id="attachment_34762" align="alignright" width="200" caption="The benefits of rapid screening are clear for products expected to be free of contamination"][/caption]

Further, given the time savings of a rapid detection method, production can be alerted sooner so less “bad” product is produced, reducing the economic and environmental impact of discarded or reprocessed goods. Additionally, customers do not have to wait as long for the replacement product.

As pressure builds to improve sustainability company-wide, making the laboratory more environmentally aware is more than a nice idea. The reduction of a few bags of rubbish, a few litres of water and a few kilowatts of power each day, multiplied by the hundreds of testing days a year, at thousands of laboratories, all adds up. So, too, does the savings in working capital.

With the growing adoption of rapid detection technology, for screening raw materials, work-in-process and finished goods for contamination, rapid detection methods offer a sustainable opportunity that cannot be missed. Rapid results create a ripple effect that benefits both a company’s economics and the environment.

Validation and regulatory concerns for laboratories

Validation and acceptance of rapid methods are often a concern for regulated industries. These issues tend to prioritise ahead of sustainability issues and some companies even discount rapid methods altogether- even though they are proven to provide significant operational and environmental benefits.

Many thousands of products around the world have already been successfully validated with rapid systems, and likely include products already being produced by many companies. Numerous global regulatory bodies support transitioning to rapid methods for release testing.

Look for a rapid systems provider who offers validation support to help get the system releasing products quickly, as well as regulatory compliance expertise. Contract analytical laboratories and contract manufacturing companies are increasingly adding rapid method equipment and expertise to assist clients with initial validation as well as with ongoing or seasonal testing. Also, suppliers with a track record of instruments successfully validated can offer significant resources and support to companies completing a validation.

Author: Jenny Woolway, Celsis International

Contact:

t: +32 (0)2 534 08 91 e: RDinfo@celsis.com