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Innovative cartridges for rapid PCR tests

8. February 2022
in News, Pharmaceuticals, Processing Technologies

PCR tests are the right choice for detect­ing infec­tion-caus­ing virus­es such as SARS-CoV­‑2. Today, no one has to wait long for the results. Qia­gen, for exam­ple, has devel­oped the com­pact QIA­s­tat-Dx ana­lyz­er, which, in com­bi­na­tion with the appro­pri­ate test car­tridges, enables real-time PCR for the rapid detec­tion of pathogen nucle­ic acids in human bio­log­i­cal sam­ples. More than 20 pathogens, includ­ing Covid-19, can be detect­ed in a sin­gle run with­in just 60 min­utes. The small test car­tridges (Fig. 1) con­tain all the nec­es­sary lab­o­ra­to­ry equip­ment in minia­ture for­mat with all sol­id and liq­uid reagents.

At the same time, they are uncom­pli­cat­ed to han­dle: The sam­ple is tak­en from the patient and insert­ed into the car­tridge. Only a few steps are required to insert it into the ana­lyz­er. The test can start after just one minute. To pre­vent the nec­es­sary liq­uids from leak­ing, the car­tridges must be absolute­ly leakproof and, as a med­ical prod­uct, must meet high qual­i­ty require­ments. At the same time, pro­duc­tion costs should remain as low as pos­si­ble, since each car­tridge can only be used once. For Qia­gen, ultra­son­ic weld­ing sys­tems are there­fore the method of choice for join­ing plas­tic parts inside the cartridge.

Large quantities with consistent quality

Today, weld­ing with ultra­sound is con­sid­ered the fastest and also the most cost-effec­tive and reli­able method of join­ing and assem­bling plas­tic parts. Key advan­tages are that no adhe­sives, fas­ten­ers or sol­vents are used; this also makes the process very envi­ron­men­tal­ly friend­ly and effi­cient. At the Barcelona site, where Qia­gen man­u­fac­tures the test car­tridges, two ultra­son­ic weld­ing sys­tems from Tel­son­ic are now in oper­a­tion (Fig. 2). One was already in use before the pan­dem­ic; the sec­ond has now been added due to increased demand. Both are housed in sound­proof booths that pro­vide effec­tive shield­ing for the employ­ees. Today, up to 2,000 cylin­dri­cal plas­tic parts are fixed inside the test car­tridges with secure and absolute­ly tight weld seams every day.

The robust and durable ultra­son­ic weld­ing sys­tems of type USP750 have already proven them­selves many times over in large-scale pro­duc­tion, not only in med­ical tech­nol­o­gy but also in the auto­mo­tive indus­try, for exam­ple. Low main­te­nance, high reli­a­bil­i­ty and long ser­vice life are the pre­req­ui­sites for this. Thanks to the high flex­i­bil­i­ty dur­ing changeover, the sys­tems are also ide­al­ly suit­ed for appli­ca­tions with small pro­duc­tion runs. In addi­tion, end-to-end process con­trol can be eas­i­ly imple­ment­ed. Weld­ing results are mon­i­tored in qual­i­ty win­dows and auto­mat­i­cal­ly eval­u­at­ed graph­i­cal­ly and sta­tis­ti­cal­ly. This guar­an­tees that the test car­tridges for the fast PCR ana­lyz­er can be man­u­fac­tured in large quan­ti­ties with con­sis­tent quality.

 

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