LFDA Lateral Flow Device Assembly – Customer Case Study

BBI Solutions chose Ginolis

BBI Solutions has served the global diagnostics industry for over 50 years, as a leading developer and manufacturer of raw materials and finished test platforms for the in-vitro diagnostics marketLooking to continually develop and improve their manufacturing capabilities and provide capacity for growing demand. BBI sought an automation system for their lateral flow manufacturing service to drive efficiencies, whilst providing flexibility to grow with their customers’ needs.

Robust and flexible manufacturing options

BBI Solutions (BBI) pride themselves in offering robust and flexible manufacturing options to cater not only for routine manufacturing production but for spiked demand or supply as part of a disaster recovery program. For technically challenging unstable manufacture or assays with high failure or reject rates, they are able to develop a programme of work to address these issues.

With choosing the modular Ginolis platform, it has given BBI additional flexibility and the ability to grow with their customer’s needs for years to come.

The line is equipped to flexibly produce up to 10 different formats of products, with minimal change over time and allows for single and multiple strip assay formats. A throughput of up to 40 parts per minute is possible without compromising quality, as vision systems can be included so that inline quality checks can be built into the assembly process.

Outsource to the experts in lateral flow

Whether a new start-up company looking for someone to manufacture their assay or a fast-growing company under pressure to meet increasing demand, BBI’s manufacturing capabilities with the addition of Ginolis’ next-generation automation technology can deliver the results required to fulfil customers’ expectations

“The Ginolis automation demonstrates our ambition and is the next phase of continued development in our contract manufacturing capability at our HQ in Wales” explains Ian Elliott, Chief Operations Officer at BBI Solutions. “The automation provides us with a modular solution for our diverse customer portfolio whilst improving throughput and reducing defect opportunities in our process. This strategic partnership with Ginolis gives BBI access to enhanced engineering capability to deliver solutions for our current and future customers’ lateral flow needs.”

BBI’s manufacturing capabilities

  • 120,000sq feet for manufacturing
  • 5 to 100K+ device batch sizes
  • Facility located in the UK (Crumlin)
  • ISO13485:2016 certified QMS system
  • Benchtop and reel-to-reel dispensing systems
  • Manual, semi and fully automated lamination systems
  • Rotary and guillotine strip cutting
  • Manual and automated assembly solutions
  • Manual and semi-automated pouching solutions
  • Buffer dispensing capabilities
  • Kit packing
  • Humidity and temperature-controlled rooms

BBI Solutions is part of the BBI Group Ltd. Contact info: www.bbisolutions.com, email: info@bbisolutions.com, phone +44 (0) 1495 363 000

This LFDA assembly line will be delivered to BBI Solutions in co-operation with IPP Ltd, our official partner of Ginolis automation systems in the UK and Ireland.  IPP contact info: sales@ippgroupltd.com,  +44 (0)1527 578972.

Ginolis LFDA

The Ginolis Lateral Flow Device Assembly (LFDA) system is a revolutionary new step in diagnostics manufacturing. The LFDA brings together intelligent automation and modularity in a desktop scale.

The world-leading lateral flow device assembly solution provides manufacturers with flexible production capacity within a desktop footprint. The LFDA-3 is built on Ginolis´ modular Xanthia robotic platform. The solution is easily adaptable and can assemble different rapid tests with minimal product specific adjustments.

To ensure flawless and high quality-operation, a versatile machine vision system is utilized for accurate positioning, defect detection, tolerance monitoring and component measurement. The machine vision guidance system yields a consistently high quality assembled device.

The Ginolis Intelligent transfer unit provides smooth and fast component movement between cells. The LFDA is controlled using  Ginolis’ Ginger software platform. Ginger is easy to use, intuitive and designed specifically for desktop automation.

Technical Specifications

  • Footprint: 1.8 m x 1.5 m
  • Compressed air: min. 6 bar
  • Power: 110-230 VAC, 50-60 Hz, 10 A
  • Speed: up to 80 pcs/min
  • Operating system: Ginolis Ginger

Main Features

  • Machine vision-guided infeed of materials
  • Strip cutter with a single card, card magazine or reel infeed
  • Vision guided component placement, strip cutting,  and assembly ensure consistent high quality
  • Quick product changeover due to minimal product-specific parts
  • LFDA is a product family and number of modules can be configured based on customer’s needs,  multiple strips, RFID tag, printing, labelling etc.

Ginolis LFDA Modules

Bottom Housing Infeed

The bottom housing infeed module consists of a  2-level conveyor bulk feeder, rotating disc and two SCARA robots. The bulk feeder mechanism provides a controlled and monitored input of housings with a customizable buffer.

Machine vision inspection ensures each housing fits QC requirements before it is placed onto the carrier for transfer to the next cell.

Intelligent Transfer Unit

Components advance along the LFDA-3 line on Ginolis’ Intelligent Transfer Units. The multi-functional system transfers the components accurately on magnetic carriers across a glass platform. With minimal moving parts, the intelligent transfer unit is low maintenance and easy to clean. Optional multilayer belt conveyer offers increased manufacturing speed.

Strip Cutting and Assembly

The strip cutting module utilizes a linear servo motor driven blade to cut strips. Vision guidance ensures precise strip width and checks for wrong marked material. The LFDA-3 is available with a single card, card magazine or reel infeed.

The cut strip is inspected for correct dimensions and the presence of pads before being positioned precisely on the bottom housing with a vision-guided SCARA robot.

The line can be equipped with several strip cutting and assembly cells, providing manufacturing of multi-strip rapid test.

Top Housing Infeed

Identical to bottom housing, the top housing infeed module utilizes a 2-level conveyor bulk feeder, rotating disc and two SCARA robots for vision-guided placement of the top housing. The housing infeed ensures a controlled and monitored input of components.

Identical to bottom housing, the top housing infeed module utilizes a 2-level conveyor bulk feeder, rotating disc and two SCARA robots for vision-guided placement of the top housing. The housing infeed ensures a controlled and monitored input of components.

Press Unit

The assembled lateral flow device is fed through a servo-driven press unit which has an adjustable force and height parameters.

After successful cassette closure, the assembled lateral flow device is transferred via the intelligent transfer unit to a final quality control inspection.

Quality Control

The Lateral Flow Device Assembly system includes comprehensive quality control. Multiple cameras and dash lights check for component features, correct positioning and proper cassette closure. After the final QC check, failed cassettes are rejected into a separate bin.

Available Options

  • Desiccant tablet or end cap insertion
  • Marking options: Printing and label application
  • Laser marking (different laser types available)
  • Inspection; UV-line, print quality inspection ETC
  • Data collection option
  • Pouching interface

Ginger Control System

  • Ginger™ – desktop automation software
  • Embedded industrial PC (Win 7 Pro, TwinCAT)
  • GIN UX Tablet User Interface
  • Machine vision system
  • Supports multiple languages

For more information on Ginolis products, please contact sales@ginolis.com.

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