Reduction in per-sensor cost
11x
0
Higher production rate than target
40%
0
Faster than manual card processing
629x
0
Case Study
Automating A/pH Sensor Production for Dialysis Consumables at Commercial Scale
From Manual Pilot Line to Fully Automated, Hands-Off Manufacturing
A medical device company developing dialysis consumables needed to transform a slow, labor-intensive sensor production process into a scalable, automated manufacturing line capable of meeting commercial demand. Ascential redesigned the sensor chemistry pattern, engineered a complete end-to-end production system, and delivered a fully automated line that exceeded throughput targets by 40% while reducing per-sensor cost by 11 times.
The Challenge
Producing A/pH sensors for dialysis applications requires precision at every stage. The sensors must meet exacting quality and accuracy standards, as their performance directly affects patient safety during treatment. For this client, the existing production process fell far short of what commercial scale required.
The pilot line was manual, producing only 40 strips per day. Output was insufficient, the cost of goods was high, and the process involved hazardous chemicals that created ongoing safety risks for operators. Manual monitoring and inspection further slowed production and introduced variability that threatened consistency. The client’s goals were clear:
Design for Manufacturability
Optimize the A/pH sensor design to support high-speed production without compromising quality or measurement accuracy.
Throughput at Scale
Transform a 40-strip-per-day manual process into a high-volume automated line capable of meeting commercial demand.
Cost Reduction
Dramatically reduce the cost of goods per sensor to support a commercially viable product at scale.
Operator Safety
Eliminate or minimize direct operator exposure to hazardous chemicals and reduce reliance on manual monitoring and inspection.
Ascential's Solution
Ascential approached the engagement as a complete manufacturing design challenge, beginning at the product level and building outward to the full production system. The first step was redesigning the sensor’s chemistry pattern to enable high-speed lamination, a prerequisite for any automated, high-throughput process. This design change unlocked the manufacturing performance the client required without compromising sensor accuracy or quality.
From there, Ascential developed a fully automated upstream and downstream production line that converts raw film into finished, packaged sensor strips. The process encompasses slitting, assembly, and packaging, all integrated into a continuous, hands-off workflow. The line was designed and certified to CE and explosion-proof standards, reflecting the hazardous chemical environment in which it operates.
To protect operators, Ascential implemented a dual-zone safety system that physically separates personnel from chemical exposure zones. Process monitoring software was integrated throughout, enabling minimal operator intervention and reducing the manual inspection burden that had slowed the previous process.
Ascential transformed a labor-intensive process into a high-speed, fully automated production line that maintained critical tolerances while improving throughput and safety.
Technical Capabilities Delivered
The production system integrates multiple engineering disciplines across the full sensor manufacturing workflow:
| Capability | What Ascential Built |
|---|---|
| Sensor Design Optimization | Redesigned chemistry pattern to enable high-speed lamination while preserving measurement accuracy and quality requirements |
| End-to-End Process Automation | Fully automated upstream and downstream line converting raw film to finished, packaged sensor strips through slitting, assembly, and packaging |
| High-Speed Lamination | Production process scaled from 40 strips per day to 42 strips per minute, a 629x increase over manual card processing |
| Dual-Zone Safety System | Engineered safety enclosure separating operators from hazardous chemical zones, with CE and explosion certification |
| Process Monitoring Software | Integrated monitoring software enabling hands-off operation with minimal operator intervention and reduced manual inspection |
Key Results
The completed manufacturing line exceeded performance targets across every key dimension, delivering both the quality and commercial viability the client required:
- 11x reduction in per-sensor cost, driven by automation and design-for-manufacturability improvements that eliminated manual labor and production variability
- 40% higher production rate than the original target, with the line operating at 42 strips per minute
- 629x faster than manual card processing, a step-change in throughput that transformed the production economics of the program
- CE and explosion-certified line, meeting rigorous safety standards for hazardous chemical environments
- Fully automated, hands-off operation with integrated process monitoring software and a dual-zone safety system protecting operators throughout production
Why It Matters
Dialysis consumables are high-volume, precision-critical products where manufacturing performance directly affects both patient safety and commercial viability. A sensor that cannot be produced reliably, at scale, and at a cost that supports market pricing is not a commercially sustainable product, regardless of its clinical performance.
This program demonstrates that design-for-manufacturability and production automation are not sequential steps. By redesigning the sensor chemistry pattern and engineering the full production system in parallel, Ascential was able to deliver a line that exceeded throughput expectations while meeting the safety and quality requirements of a regulated medical device environment. The result is a production platform that positions the client to scale with demand, compete on cost, and maintain the consistency that dialysis patients require.
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