Companies today are working to optimize their manufacturing facility and are taking steps to manage expenses by introducing automation and streamlining process flows on the production floor. For the attention that’s been given to operational efficiency, there is still another way to literally cut days or more out of the production cycle timeby reducing inspection time and implementing a high-throughput, rapid microbial screening system for faster product release. Many manufacturing facilities are still testing for microbiological contamination using a method that dates back to the late 1800s. This “traditional plate method” requires a lab technician to collect and prepare samples in a growth medium, then wait until a set number of days have passed before releasing that product lot to distribution. The wait time for test results is typically three to five days for non-sterile consumer products. During this time finished goods are unavailable, on a “QA hold”, adding days to production cycle times and tying up critical working capital that could be better invested elsewhere. Tying up this much extra working capital to support bloated inventories and extended lead times leaves facilities lethargic and far from efficient.
 
Screening products for microbial contamination is an important step in ensuring product quality. What’s out of proportion is the time it takes to get results with traditional methods, given the readily available testing options. Rapid microbial testing provides a faster alternative to the traditional, time-consuming method to see if microorganisms are present. Today’s rapid screening systems can provide accurate results on a broad range of product types in as few as 24 hours, trimming four days from the average production cycle. These alternative methods are validated and accepted by regulators around the world.
 
A rapid microbial testing system represents a new best practice for manufacturers whose profitability can turn on cycle time speed and supply chain efficiency. By detecting a contamination event earlier, followed by using an accurate identification solution, manufactures can release replacement lots faster, reducing the volume of goods that must be scrapped, and can recover faster — both operationally and financially.
 
Even if you’re managing a fairly efficient operation, most companies have room for improvement. Implementing rapid screening goes a long way toward improving your quality control efficiencies with a host of quantifiable benefits. The potential cost savings and reduction in production cycle times and working capital requirements may enable your company to pursue more productive endeavors. Take a close look at your current microbial testing methods to see if you can reduce your time to release product. That old method from the 1800s may be comfortable, but it doesn’t do a thing for your bottom-line.