At the end of 2023, Pro-Tot Oy carried out a major automation project for Reagena Oy, a Finnish company operating in the diagnostics sector. Reagena felt it necessary to integrate its existing test cassette assembly and packaging equipment into a single, seamless system. The project aimed to improve the functionality of the rapid test manufacturing process and to combine two separate production automation systems into a more efficient whole, whilst at the same time refining quality control.
“At the heart of the project was the need to resolve issues relating to the reliable cutting of dry-material pouches on the packaging machine, and to ensure that every test cassette met strict quality requirements. The new monitoring system checks the surface quality of the test cassettes, as well as the two-dimensional Data Matrix codes and production batch codes printed on the products. The machine vision system ensures that there are no defective products on the production line, and the rejection unit removes substandard products from the line,” explains Toni Kolkka, Project Manager at Pro-Tot Oy.
“The project involved integrating existing automation into a completely new production line. Pro-Tot made sensible and practical choices, taking into account the nature and requirements of the project. They tackled the challenges they identified creatively and expertly, which was a key factor in the quality of the end result,” says Achim Müller, Production Manager at Reagena Oy.
A COMPREHENSIVE AUTOMATION SOLUTION
The delivery comprised three key modules specified by the client: Module A, Module B and Module C.
MODULE A – FUNCTIONALITY USING MACHINE VISION AND PERIPHERAL EQUIPMENT
Module A was a key component of the automation system supplied. Module A is situated between the assembly and packaging units and comprises a control panel and control centres. This solution enabled the existing equipment to be integrated into a single system. Among other things, the module handles the transport and reception of products, the removal of dust and other contaminants, and the input of batch-specific data. In addition, each cassette is inspected by a machine vision system for any potential faults. Module A meets demanding standards in terms of equipment and functionality, offering the ability to halt production via automation and achieving a high rejection rate thanks to machine vision.
MODULE B – IMPROVING THE EFFICIENCY OF THE PACKAGING MACHINE
Module B was designed to resolve the customer’s issue regarding the accuracy of the cutting point on dry-material bags. The previous equipment did not monitor the cutting point on the dry goods bags, which led to occasional incorrect cuts and, consequently, product rejection.
“The problem was how to get the machine to recognise the cutting mark printed on the dry ingredient bag. We realised that the correct cutting point would be achieved when the laser sensor detected the cutting lines on the bag. After some testing, we got the machine to work as required,” says Kolkka happily.
Module B was seamlessly integrated into the existing system and improved the operation of the packaging machine, reducing errors and enhancing the performance of the packaging process.
MODULE C – SAFE TRANSPORT OF PACKAGED GOODS
Module C focused on the safe transport of packaged products from the packaging unit to the collection point. It was designed to ensure the integrity of product packages during transport and to facilitate their integration into the overall packaging process. Among other things, Module C improved workplace ergonomics and integrated the equipment into a single system, thereby enhancing the line’s functionality.
PRACTICAL BENEFITS FOR THE CUSTOMER
The main objective of the project was to improve the performance and quality control of Reagen’s production process and to meet the customer’s specified lead time requirement. The requirement for the new equipment was to transport test cassettes from the cassette-loading machine to the packaging machine at four-second intervals. The new equipment is capable of even faster cycle times than four seconds.
“During a two-hour continuous performance test, the new equipment produced the target number of test cassettes. The pass rate was 99.84 per cent, which comfortably met the customer’s requirement of >95 per cent,” says Kolkka.
As a result of the project, the client achieved a significant improvement in performance, which is clearly reflected in the increased efficiency of the production line.
“The investment has opened up discussions on contract manufacturing with a new customer segment that requires greater capacity. The benefits have not yet materialised, but we estimate that there is considerable potential,” says Müller.
THE IMPORTANCE OF COOPERATION AND A RELIABLE PARTNER
The successful outcome was largely due to close cooperation with both the client and the subcontractors, as well as continuous communication, which proved to be key factors in the project’s successful progress. The Reagena team emphasised that Pro-Tot’s technical support and maintenance were easily accessible and, when needed, provided promptly, which brought flexibility and efficiency to their day-to-day operations.
“The Pro-Tot professionals who took part in the project demonstrated their expertise and were approachable. The atmosphere of open discussion enabled us to exchange ideas and outline future possibilities during the project,” says Müller.
Based on her experience, Reagena warmly recommends Pro-Tot as a partner to others, recognising the company’s professionalism and commitment to customer satisfaction.
REAGENA OY
Reagena is a Finnish biotechnology company that develops, manufactures and sells internationally recognised, high-quality products to healthcare laboratories, pharmacies and industry.
Reagena’s core areas of expertise are:
- The development and manufacture of rapid immunological tests and enzyme-linked immunosorbent assay (ELISA) methods for the diagnosis of infectious diseases such as Lyme disease, tick-borne encephalitis and hantavirus infections
- Manufacture of reagents, staining solutions, buffers and fixatives for the life sciences and industry
- Contract manufacturing and product development services
- Distribution of leading diagnostic brands in the Nordic countries.
