Adhesive buildup can be the single biggest automation challenge for machine builders and the single biggest headache for IVD manufacturers. Mitigating this problem can have a dramatic effect on product yield and manufacturing efficiency.

The labor-intensive process of cleaning adhesives from machine components is a tedious and time-consuming task. This process involves manual scraping and using solvents that are neither human nor product friendly. 

Cleaning solvents mixed with adhesives creates additional challenges. This combination has a viscosity that allows the sticky solution to permeate into places on a machine that should not otherwise be exposed to adhesives. Machine components, such as vacuum ports and precision mechanisms, can plug and gum up to the extent that major part maintenance will frequently be required.

Not a One-Size-Fits-All Solution

Creative attempts at adhesive removal range from dry ice blasting and ultrasonic cleaning to a hazmat extravaganza of manual and labor-intensive tedium. The problem with automated attempts to clean adhesives is that these processes are proportionally as hard on the parts being cleaned as they are effective at cleaning, which can lead to increased part maintenance and replacement costs.

IVD manufacturers must recognize this problem and work with their suppliers and automation partners early in the product development process. A manufacturer’s scientist who focuses on new product development and technological breakthroughs is probably not an automation expert. In some cases, it may be too late in the process to make fundamental changes to the product due to time or validation constraints.

Choosing the Right Adhesive Is the Key

Designing for adhesive mitigation is critical. Proper clearances, selection of materials, coatings, and quick replacement of parts subject to adhesive buildup are all very important. Proper machine design for adhesive mitigation can mean stopping to clean once every few hours instead of every 20–40 minutes. Choosing the right adhesive can also extend intervals between cleanings to days or even weeks. An IVD manufacturer with a 24/7 production operation can imagine the negative impact an inappropriate adhesive can have.Designing IVD products for manufacturability and automation is a key to success. Optimizing the materials selected for products is as important as product geometry. In many cases, the variety of material choices available for most products is plentiful.    By Ted Meigs  
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