Advanced integrated automation solution

A diagnostics manufacturer specializing in syndromic infectious disease testing (SIDT) relied heavily on manual processes to fabricate single-use testing cartridges — closed-system disposable modules containing all chemistry required to isolate, amplify, and detect nucleic acid from patient samples. Manual handling introduced contamination risk at every touchpoint, directly threatening the integrity of diagnostic results. Variable human interactions reduced repeatability and yield, limiting production capacity. In an industry where accurate, timely results can determine patient outcomes, the status quo was unsustainable — the company engaged Swiss machine builder Rychiger AG to replace the line with a fully automated, integrated solution.

Rychiger AG developed the MC 1400, a fully enclosed automated assembly machine built around Rockwell Automation's MagneMotion independent cart technology (ICT) — a precision rail-based transport system that moves cartridge components through multi-stage assembly with full track-and-trace capability. The MagneMotion ICT's 'pitchless' conveyor design eliminates bottlenecks by allowing the slowest process station to run in parallel. Overall machine control integrates an Allen-Bradley ControlLogix L8 PAC with an Allen-Bradley GuardLogix L7S PAC for safety, Kinetix servo drives across multiple axes, and third-party Stäubli robots. FactoryTalk View SE SCADA and ThinManager centralize HMI management across two VersaView 5200 thin clients. All communication runs over EtherNet/IP using Stratix 5400 and 5700 managed switches, meeting the customer's CPwE (Converged Plantwide Ethernet) requirements.

The MC 1400 delivered a fully integrated control and production solution that fundamentally changed how cartridges are manufactured:

• Reduced manual interactions — operators no longer handle cartridges directly; the enclosed machine keeps human contact out of the process entirely
• Improved repeatability and quality — consistent servo-driven motion replaces variable manual handling across every assembly stage
• Reduced contamination risk — shadowless internal lighting, easy-clean surfaces, and minimal trap points in the enclosure design systematically address contamination vectors
• Highly scalable architecture — stations can be taken offline for maintenance without halting the line; the system is configurable for future capacity or process changes

The conjoint development process between Rychiger and the end customer, including MagneMotion simulator trials before physical build, shortened validation cycles.

• MagneMotion ICT's simulator mode allows cycle time estimation before hardware is built — reduce validation risk by modeling throughput scenarios early.
• Tripling up on bottleneck stations rather than slowing the whole line is a concrete architectural strategy for maximizing throughput on multi-stage assembly.
• Centralized HMI management via ThinManager simplifies multi-station machine design and supports remote access for maintenance — worth specifying from project outset.
• Enclosure design is a contamination control measure, not just an aesthetic choice — shadowless lighting and wipe-clean surfaces should be engineered requirements in regulated manufacturing.
• Integrated servo architecture (MagneMotion + Kinetix) pays dividends in maintainability: stations are interchangeable and the upgrade path is straightforward.