Carly’s brow furrowed in concentration as she scrolled through seemingly endless search results. Finding an automated liquid handler that fits inside their biological safety cabinet (BSC) was proving trickier than she’d anticipated.
Earlier that morning, Carly had been excited. The first few liquid handlers she viewed had promising features that were sure to improve the lab’s workflows. But as she clicked through page after page, her initial optimism morphed into disappointment. Nothing that met even her most basic requirements seemed to work. Sure, some liquid handlers technically fit inside the cabinet, but not without disrupting the BSC’s airflow, putting both her staff and their research at risk.
“There’s got to be a way,” Carly sighed. Closing her laptop, she felt her automation dreams warping into a logistical nightmare.
As the prevalence of automation equipment—promising increased efficiency, precision, and throughput, continues to rise—many labs are finding themselves at a similar crossroads for sensitive workflows. Standard BSCs, designed with a one-size-fits-all approach, continue to lack the space and features needed to safely integrate this equipment.
Challenges of integrating automation equipment into standard BSCs
Incorporating automation equipment into your workflows not only boosts efficiency but also propels scientific innovation. However, if a risk assessment determines that the equipment must be enclosed, labs face a unique challenge, as BSCs are typically built to accommodate small equipment.
Automation equipment like liquid handlers, cell sorters, flow cytometers, or bioprinters are intricate and bulky, typically exceeding the size and weight capacities of standard BSCs. But, even if the equipment physically fits in the space, its presence can obstruct proper airflow, preventing the cabinet from providing containment and jeopardizing safety. Additionally, standard BSCs often lack the necessary flexibility to position automation equipment in a way that is both ergonomic and conducive to its operation.
These limitations extend beyond physical size. Automation equipment can be sensitive to vibrations, require a large power supply, and generate excess heat during operation. Standard BSCs are not designed to accommodate these factors, potentially leading to equipment malfunctions or compromised results.
Enhancing safety and efficiency with custom BSCs
So, how can a lab safely work with automation equipment inside a BSC? The answer lies in custom BSCs. Custom models shift the focus from fitting your equipment inside the cabinet to fitting the cabinet around your equipment.
The first consideration when designing a custom BSC is often the dimensions, which can be tailored to accommodate large or non-standard equipment, ensuring ample room for manipulation, maintenance access, and proper airflow. It’s also essential to account for the weight of the equipment, as the cabinet may require reinforcement.
Beyond size and weight, additional specifications like vibration sensitivity and temperature requirements should be addressed. Accommodations for these factors can include extra stability measures and the incorporation of heating or cooling coils. These features also help maintain precision and reduce the risk of equipment failure or malfunction.
The final piece of the puzzle is to consider the process or workflow that needs to be performed. This can lead to the inclusion of relevant ergonomic features and extra workspace for sample preparation or equipment-generated biohazardous waste storage. Integrating negative pressure pass-throughs on the side of the custom BSC to port tubing, power cables, data cables, or other connectors can also be beneficial, particularly for labs with non-contained but associated equipment. Additionally, if required, a shelf can be built on the exterior of the BSC to support this extra equipment if there is no existing casework or if it is more convenient for the user.
Service and maintenance procedures should also be considered when evaluating workflows, as ease of access is essential for reducing downtime and extending equipment lifespan. Some features that facilitate this include a slide or roll-out work zone, outward-swinging double doors, and back or side access panels.
If any major modifications are made during the customization process, the BSC will no longer be certified to meet biosafety standards such as NSF/ANSI 49 and EN 12469. Major changes include producing cabinets of non-standard sizes, providing tailored access (e.g., side access), incorporating robotics, and designing the cabinet to fit a specific space and instrument. The ideal custom BSC manufacturer will understand these challenges and be well-equipped to address them. Lab managers can identify such manufacturers by seeking those that offer additional testing, allowing for validation of any changes as they are made. This ensures that the final product meets strict safety and regulatory standards while aligning with the users' requirements and specifications, ultimately improving efficiency and safety for lab personnel.
Case study: Developing large-scale containment solutions
An example of the benefits of custom BSCs comes from a global pharmaceutical company that required a large-scale containment solution for their new automation platforms. To overcome this challenge, the organization partnered with NuAire, an equipment manufacturer specializing in custom containment solutions.
The collaborative process began with an in-depth discussion between the pharmaceutical company, the manufacturer's engineers, and a custom product coordinator. This allowed the manufacturer to determine the automation equipment’s requirements and the end users’ needs. During these conversations, the company expressed concerns about needing a larger enclosure to contain the oversized equipment. However, NuAire’s commitment to safety and proven technical expertise helped quickly alleviate these concerns.
The design process then moved into a refinement phase in which engineering drawings were exchanged between the two teams to create a final, optimized design that ensured functionality while maintaining safety. The pharmaceutical company particularly appreciated the manufacturer’s attention to detail throughout this process, as they considered every aspect, including seemingly minor details such as whether the BSC could fit through standard doorways for easy delivery and installation.
NuAire’s approach to BSC customization
Whether it’s a simple adjustment or something that has never been done before, NuAire has the expertise to make it happen. Backed by decades of experience, NuAire routinely reshapes the inner and outer dimensions of both class II BSCs and laminar flow hoods to create brand-new units that integrate seamlessly into unique lab workflows while providing the necessary level of protection.
NuAire’s customization process is highly customer-centric, beginning with a thorough consultation to understand a lab’s installation requirements and workflows, along with the automation equipment’s specifications. Following this initial discussion, NuAire’s team of engineers and product coordinators work closely with the client to draft a unique design. Once the cabinet is built, it is thoroughly tested and carefully shipped. But NuAire’s support doesn’t stop there; their expert service team and global network of sales partners are available to assist with installation and answer any questions, such as “How should a custom cabinet be certified?”
Safety is paramount for NuAire, as emphasized by their president and chief executive officer, Bill Peters, “We follow NSF/ANSI 49 for containment performance and UL 61010-1 for electrical/mechanical safety on all customizations.” By request, NuAire will also perform additional testing, such as videotaped airflow smoke visualization with simulated equipment, to aid in the field certification process and provide peace of mind.
Beyond the initial design and installation, NuAire provides ongoing troubleshooting and support services to ensure their custom equipment continues to perform at its best throughout the entirety of its lifespan, helping labs minimize downtime and maximize their return on investment.
To learn more, visit NuAire’s Custom Lab Automation Enclosures web page.
References
Building a Custom Biosafety Cabinet: https://www.nuaire.com/resources/building-a-custom-biosafety-cabinet-white-paper
Custom Biosafety Cabinets for Robotics and Automation: https://www.nuaire.com/resources/sanofi-custom-biosafety-cabinets-for-robotic-automation-white-paper
Customizing Biosafety Cabinets a Holistic Approach: https://www.nuaire.com/resources/customizing-biosafety-cabinets-a-holistic-approach-webinar
Tailor Made Biosafety Cabinets for Automation: https://www.nuaire.com/resources/tailor-made-biosafety-cabinets-for-automation-video