The production of immunoassays requires the highest accuracy and zero-error tolerance. Each component must be precisely positioned and assembled to ensure that the test functions correctly. The system must be flexible enough to meet various production requirements and ensure a high throughput rate.

The automated high-speed assembly line consists of two large sections: The lower base part of the immunoassay is manufactured on one section of the machine, while the upper part, consisting of the lid and filter, is manufactured on the other section. Both are then laser-welded together. The two assembly streams consist of a series of specialized stations such as high-precision dosing units, precise filter placement with subsequent thermal welding (heat-stacking) and multiple lasers that cut, mark and weld. The quality of these processes is closely monitored by camera inspection stations along the entire assembly line before the label is finally applied to the product.

"The special thing about the system is the extremely short cycle time: only 3 seconds are needed to pass through each of the 20 stations. This means that around 1,200 products can be produced on our line in one hour," says PIA mechanical engineer William Wargel.